Material Requirements Planning (MRP) software helps manufacturers determine what materials to purchase, how much is needed, and when materials should be available for production. For process manufacturers, MRP software plays a critical role in balancing inventory levels, production schedules, and customer demand while reducing waste and operational costs.
Unlike discrete manufacturing, process manufacturers work with formulas, recipes, batch production, variable yields, shelf-life constraints, and strict compliance requirements. Generic planning tools often struggle to manage these complexities.
BatchMaster MRP software is specifically designed to help food, beverage, chemical, pharmaceutical, nutraceutical, and personal care manufacturers plan materials accurately and keep production running smoothly.
What needs to be produced, and when — the demand driver for all MRP calculations
What ingredients go into each product — in process manufacturing, this is a formula, not a BOM
What stock is currently available, on order, expiring, or on QC hold
Traditional MRP systems are often designed for discrete manufacturing and may not adequately support the requirements of process manufacturers. Process manufacturers must manage:
Procurement over-ordered mango extract. Again. $22,000 of perishable raw material in the cooler because the MRP suggestion didn’t account for the 14% process loss in the concentration step — so it suggested buying 14% more than it should have.
Meanwhile, there’s a shortage on the proprietary fragrance compound for next week’s run. The reorder point was set for individual units — not batch-sized lots. The shortage won’t show up in the system until Thursday when the batch ticket is being picked. The purchase order won’t arrive for 10 days. Production will sit idle for half a shift. Expedite fee: $850.
MRP and ERP are often used interchangeably — but they solve different problems at different scopes. Here’s how they compare.
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Capability
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MRP Software
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ERP Software (incl. BatchMaster)
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|---|---|---|
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Primary focus
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Material planning, inventory, and production scheduling
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End-to-end business management across all departments
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Material requirements planning
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Core function
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Included as a module
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Inventory management
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Basic stock levels
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Full lot traceability, expiry, QC hold
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Production scheduling
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Basic scheduling support
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Full MPS with capacity and resource planning
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Quality control
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Not included
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QC workflows, CoA, in-process testing
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Finance & accounting
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Not included
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Integrated GL, AP/AR, cost accounting
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Sales & order management
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Not included
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Customer orders drive production and MRP
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Procurement & supplier management
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~ Purchase recommendations only
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Full PO lifecycle, supplier portals, lead time management
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Process manufacturing specifics
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Generic only — no yield, co-product, or expiry logic
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Yield-adjusted, batch lot-sizing, co-product netting, perishable awareness
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Yield-adjusted material requirements from historical process data
Batch-aware lot sizing with supplier pack size constraints
Co-product and by-product inventory netting against requirements
Time-phased requirements tied to the production schedule
Perishable raw material expiry awareness in planning calculations
Supplier lead time and safety stock management
Min/max and reorder point management with batch-size floors
Multi-level formula explosion for complex multi-step processes
Demand scenario modelling — what-if before committing to a customer order
Recipe yield management, allergen traceability, seasonal ingredient planning
GMP-compliant batch planning, potency-adjusted requirements, stability shelf-life awareness
Active ingredient yield planning, certificate of analysis (CoA) tied purchasing
Reaction yield modelling, co-product and by-product netting, hazardous material handling
Fragrance compound planning, INCI compliance, perishable ingredient expiry
Pigment dispersion yield, VOC-compliant formulation planning, seasonal demand shifts
Material Requirements Planning (MRP) software helps manufacturers plan, schedule, and manage the raw materials required for production. For process manufacturers — such as those in food, chemical, pharmaceutical, nutraceutical, and personal care industries — MRP software ensures the right materials are available at the right time, reducing production delays, minimising waste, improving inventory control, and supporting efficient manufacturing operations.
BatchMaster MRP system provides real-time visibility into inventory levels and future material requirements. By helping manufacturers purchase only what is needed and when it is needed, it reduces excess stock, minimises carrying costs, and improves cash flow.
Yes. BatchMaster software aligns material availability with production schedules, helping manufacturers optimise resource utilisation, avoid production delays, and improve on-time order fulfilment. This enables more efficient and predictable manufacturing operations.
MRP software focuses primarily on material planning, inventory management, and production scheduling. ERP (Enterprise Resource Planning) software provides a broader business management solution that integrates manufacturing, inventory, procurement, quality control, finance, sales, and supply chain operations. BatchMaster combines advanced MRP functionality within a comprehensive ERP platform, enabling manufacturers to manage their entire business from a single system.
BatchMaster MRP software continuously monitors inventory levels, open orders, supplier lead times, and production requirements. It automatically identifies potential shortages and generates timely purchase recommendations, helping manufacturers maintain uninterrupted production and meet customer demand.
BatchMaster manufacturing MRP software supports food & beverage, chemicals, pharmaceuticals, nutraceuticals, cosmetics, paints, coatings and other process manufacturing sectors across the UK and Europe. Any batch-process manufacturer that experiences yield variability, recovers co-products, or works with perishable raw materials will benefit from BatchMaster’s process-aware material planning software.
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