Coal Pilferage Detection System India — Eliminate In-Transit Cargo Losses

Indian coal plants lose thousands of crores every year to in-transit pilferage. The losses happen on roads with GPS coverage, on routes used for decades. They persist because standard tracking cannot detect the physical act of theft.

A coal pilferage detection system changes this by combining GPS with activity sensing using sensors — IoT devices that capture the physical signature of an unloading event wherever it occurs.

The Scale of the Problem

5–15% of cargo lost per trip in unmonitored corridors

A plant receiving 500 trucks/month at 25 tonnes loses 625–1,875 tonnes/month to pilferage

At ₹3,000–4,000/tonne: ₹1.9–7.5 crore per month per plant

Dispute resolution rate without sensor evidence: effectively zero

Why Pilferage Persists Despite GPS

GPS tracking has been on Indian coal fleets for over a decade. Pilferage rates have not declined proportionally. The reason: GPS tracks location, not action.

Activity sensing using sensors closes this gap. IoT sensor data doesn't depend on GPS connectivity — it captures what physically happens on the truck body regardless of network availability.

How Intugine's System Works

Hardware: Proprietary IAS IoT device fitted to the tipper body. Captures physical activity data continuously. Stores locally if network unavailable.

Activity sensing algorithm: Rolling window analysis classifies each segment as transit, loading, unloading, or idle. Unloading events outside authorised geofences trigger alerts.

Risk scoring: 9-parameter risk score per trip, issued to plant before vehicle arrives.

Control tower: 50+ analysts monitoring 24×7. Alert triage, driver escalation within 2-minute SLA.

Evidence log: Every flagged event creates an immutable record for transporter penalties and legal action.

Deployment Timeline

Week 1: Devices fitted, geofences configured, risk zones mapped. Week 2: Control tower briefed, live monitoring begins. Week 3–4: Full deployment active. Risk scores issuing per trip. Month 2+: Transporter performance data and monthly risk reports accumulating.

ROI: Conservative Calculation

500 trucks/month × 5% pilferage × 25 tonnes × ₹3,500/tonne = ₹21.9 lakh/month saved Platform cost: ~₹40/trip × 500 = ₹20,000/month Net monthly saving: ~₹21.7 lakh. Payback: immediate.