IoT and AIDC Dispatch Automation for India's Largest Ice-Cream Manufacturer

01 · The Challenge

India's largest ice-cream manufacturer ships a vast catalogue of frozen products from cold stores to distributors across the country, against the clock and the melting point. Dispatch ran on paper challans and manual counting, so loads were miscounted, wrong SKUs went onto trucks, cold-store dwell time stretched, and there was no live view of what left the dock or whether the cold chain held.

• →Manual, paper-based counting at dispatch led to miscounts and wrong-SKU loading
• →No real-time visibility of what was picked, staged, and loaded onto each vehicle
• →Cold-chain exposure during staging and loading was not monitored or recorded
• →Slow truck turnaround at the dock during peak season
• →No single source of truth linking orders, picks, and actual dispatched quantities

02 · Our Approach

We designed an IoT and AIDC (Automatic Identification and Data Capture) layer that sits over dispatch: every carton and pallet is barcode or RFID tagged, handheld and fixed scanners verify each item against the order as it is loaded, and IoT sensors watch cold-store and loading-bay temperature. All of it streams into a custom dispatch application with live dashboards, so a load is only cleared when the scans match the order.

• ✓Barcode and RFID tagging (AIDC) on cartons and pallets for scan-verified identity
• ✓Handheld and dock-mounted scanners that check every item against the order at loading
• ✓IoT temperature sensors across cold stores and loading bays, logged per dispatch
• ✓A custom dispatch app that reconciles orders, picks, and scanned loads in real time
• ✓Live dashboards and alerts for supervisors on the dock and planners in the office

03 · Solution Delivered