How All American Poly Slashes Inventory Shrink with Crosser and IFS Cloud

All American Poly, a leading U.S. producer of polyethylene film products, has achieved over $5 million in annual savings, eliminated 100% of raw material inventory shrink, reduced finished goods shrink by 200%, and unlocked real-time production visibility — all by modernizing its operations with IFS Cloud and Crosser.

Facing the limits of a highly customized legacy system and disparate data sources, All American Poly set out to consolidate its operations under a single ERP platform. The company selected IFS Cloud as its core business system — and chose Crosser to bridge the gap between shop floor data and enterprise processes, enabling fast, accurate insights and dramatically reduced implementation time.

“All American Poly is in business to make products, not create software. It was clear the company needed to find a best-in-breed commercial ERP system that could rapidly consolidate all the business dimensions and operations into a single turnkey platform,” — Joseph Adamski, IT Director, All American Poly

Fast-Tracked IoT Integration with Crosser

A major requirement for the transformation was the ability to ingest and act on real-time IoT data from the production floor. This is where Crosser played a vital enabling role. With Crosser’s low-code, edge analytics platform, All American Poly was able to connect its blending systems and machine data directly to IFS Cloud within hours - something that had previously taken months.

“Historically, we lacked the ability to ingest connected factory IoT into core business processes. A job order might run for three to four days, so we want to accurately understand raw material consumption through our blending components. That capability was absent before implementing Crosser alongside IFS,” said Adamski.

“In the first product demonstration, Crosser successfully posted data to IFS Cloud... My developer estimated the company had just saved around 400 hours of work. We were instantly sold,” says Adamski.

Within just 20 hours of implementation consulting, Crosser was connected to live blending systems, publishing IoT observations into IFS – an achievement that had previously taken six-to-nine months’ work with competitor products.

Enabling Real-Time Decisions & Operational Efficiency

Crosser acts as a real-time bridge between machines and ERP, enabling minute-by-minute insight into material consumption, waste, and labor utilization. This data gives All American Poly the visibility it needs to:

• Accurately track raw material usage
• Understand true production costs
• Optimize margins and competitiveness by product
• Power AI-driven planning and schedule optimization

“With Crosser capturing and interpreting data minute-by-minute to IFS, we can instantly see precise material consumption and waste stream costs. Through insights for machine labor and materials we can understand our margins and competitiveness for different products to make informed production decisions going forwards,” said Adamski.

Transformation Highlights

Thanks to the combination of IFS Cloud and Crosser, All American Poly has:

• Reduced finished goods inventory shrink by 200%
• Eliminated raw material shrink (100% reduction)
• Realized $5M+ in annual savings
• Achieved Safe Quality Food (SQF) certification using traceability and compliance data
• Enabled sustainability reporting, including PFAS-free and PCRP tracking
• Replaced 14-day delivery windows with confirmed delivery dates
• Prepared for AI-driven demand planning and manufacturing optimization

Read the full case study on the IFS website.