When Walki Group set out to modernise its global operations, the ambition was not simply to replace systems. it was to redefine how its manufacturing business operates in a world of increasing complexity, sustainability demands, and regulatory pressure.

As a leading producer of fibre-based, sustainable packaging solutions, Walki operates across multiple countries, technologies, and product lines. Its conversion processes, spanning laminating, coating, slitting, sheeting, and rewinding, are inherently complex, requiring precise coordination among materials, machines, and customer requirements.

For years, this complexity was managed through a combination of legacy systems and site-specific practices. While effective locally, this fragmented landscape limited visibility and made it difficult to optimise operations globally. At the same time, rising expectations around traceability and regulatory frameworks such as EUDR added urgency to the need for transformation.

Walki’s response was a bold, multi-year program to establish a unified digital foundation for processes and systems internally referred to as the “One Walki Way.” A foundation for future growth.

At the heart of this transformation sits Microsoft Dynamics 365, implemented in collaboration with Digia, providing a consistent backbone for finance, supply chain, and enterprise processes. But for Walki, true transformation required more than ERP harmonisation. It required deep, industry-specific capability at the manufacturing level.

To address this, Walki partnered with Greycon. Over the course of past five years, Greycon worked alongside Walki and Digia to bring advanced planning, scheduling, trim optimisation, and manufacturing execution into a single, connected environment tailored to fibre-based converting.

In this environment, production is no longer planned in isolation, but it is optimised.

Customer demand captured in Dynamics 365 flows directly into Greycon’s planning and optimisation platform, where the complexity of converting operations is fully modelled. Machine constraints, material[EO1]  characteristics, raw material availability, changeovers, and delivery priorities are all considered simultaneously. Advanced optimisation algorithms determine not only when production should happen, but how it can be executed most efficiently.

A critical element of this is, of course, planning and scheduling, but also trim optimisation. In fibre-based industries, even small inefficiencies in cutting patterns can result in significant material waste. Greycon’s optimisation capabilities enable Walki to maximise material utilisation while maintaining strict adherence to product specifications.

The result is a production plan that effectively combines Make-to-Order and Make-to-Stock demand, automatically generating realistic and optimal inventory replenishment orders that are ready for execution on the shop floor. From there, the process continues seamlessly into manufacturing execution through GreyconMill™, where production is monitored and managed in real time. As materials move through the converting process, data is continuously captured—tracking production performance, material consumption, and quality outcomes.

This creates a closed-loop system in which planning and execution are tightly aligned. Plans are grounded in operational reality, while real-time feedback continuously improves future planning decisions. At the same time, production data is fully integrated back into D365, supporting shipping execution, inventory management, and costing processes.

Beyond operational efficiency, this integration enables a new level of traceability. Every material, process step, and output can be tracked and linked across the production lifecycle. This capability is increasingly critical in supporting sustainability commitments and meeting regulatory requirements such as EUDR, where transparency and traceability are essential.

The success of the transformation was not driven by technology alone. It was built on close collaboration between all parties involved.

Walki’s internal teams played a central role in defining and driving a standardised operating model across sites. Greycon contributed deep expertise in fibre-based manufacturing, ensuring that solutions reflected real-world operational complexity. Digia, as the Microsoft Dynamics partner, provided the integration and ERP foundation that connected the entire ecosystem. Walki is a great example of both Greycon and Digia’s capability of delivering international ERP implementations requiring industry expertise in packaging manufacturing sector.

Together, the teams worked as a unified programme, aligning business processes, solving challenges, and delivering a solution capable of scaling across Walki’s global footprint.

By November 2025, the final sites went live, marking the culmination of a four-year journey. What emerged was more than a modern system landscape, it was a fundamentally new way of operating.

Walki now runs on a connected digital platform where planning, production, and business processes are seamlessly integrated. The company benefits from improved efficiency, reduced waste, and greater visibility across its operations. At the same time, it is better equipped to meet the demands of customers, regulators, and a rapidly evolving sustainability landscape.

Looking ahead, this foundation positions Walki to continue innovating in fibre-based packaging while scaling its operations with consistency and control.

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