Mine-to-Plant Visibility for Coal — Inbound Tracking & Halt Analysis India

For a thermal power plant or steel mill in India, inbound coal is the most critical material flow. Yet most plants have zero visibility between the colliery dispatch and the plant weighbridge.

The 5-Stage Mine-to-Plant Journey

Stage 1 — Loading at Mine: GPS + activity sensing IoT device fitted. Trip auto-created with source, destination, driver, vehicle, and expected weight. Tarpaulin sealed, photos captured.

Stage 2 — In-Transit Tracking: Minute-level GPS updates. Platform monitors for route deviation, overspeeding, and halts. Activity sensing runs continuously.

Stage 3 — Halt Detection & Analysis: Every halt beyond the threshold triggers analysis: location identified, duration assessed, sensor data reviewed for unloading activity, risk score updated live.

Stage 4 — Gate-In at Plant: Geofence trigger on arrival. Complete trip risk score pushed to security dashboard before truck reaches weighbridge. High-risk trucks directed to special sampling without slowing normal operations.

Stage 5 — Unloading Validation: Activity sensing confirms physical offloading at the plant. Farthest unloading point logged. Delivered weight compared against dispatch. Dispute-proof delivery record created automatically.

Halt Classification: Beyond Duration

Standard GPS flags halts by duration alone. Intugine adds location intelligence:

Safe zone halts — near plant in known congestion areas. De-prioritised.

Neutral halts — roadside rest during expected rest period. Low risk.

Suspicious halts — market area or settlement with no expected purpose. Medium-high risk.

Red zone halts — known pilferage location. Immediate alert regardless of duration.

This reduces false positive alerts by ~60% while catching more genuine risk events.

ERP and LIMS Integration

SAP/ERP: Trip completion syncs, updating inbound coal inventory and triggering GR posting

LIMS: High-risk flags flow to quality lab, triggering special sampling

Weighbridge: Risk score visible at operator terminal before truck drives in

Deployments active on routes from Jharkhand/Odisha collieries to plants in Rajasthan, Gujarat, Maharashtra, and Tamil Nadu — customers include Hindalco and Vedanta.