Steel Plant Inbound Logistics Tracking — Raw Material Visibility India

An integrated steel plant consumes three primary raw materials in bulk: iron ore, coking coal, and limestone — all moving via road from mines, ports, and quarries. Each stream has its own supply corridor, its own risk profile, and its own pilferage exposure.

Most steel plants track none of it in real time.

The Three Raw Material Streams

Iron Ore: High-value, high-volume. Primary pilferage risk is mid-route unloading and grade substitution. Corridors: Odisha/Jharkhand mines, coastal ports (Paradip, Vizag).

Coking Coal: Imported or domestic. High per-tonne value (₹15,000–25,000/tonne for imported coking coal). Moves from ports or railway yards to plant via road for last-mile. High theft incentive.

Limestone: Lower value but extremely high volume — steel plants consume 200–400 kg of limestone per tonne of steel. Small percentage losses across large volumes accumulate into significant costs.

One Platform, Three Streams

Intugine tracks all three raw material inbound streams on a single platform:

Unified tracking dashboard across all material types

Per-commodity risk zone configuration (different pilferage hotspots for ore vs coal vs limestone)

Per-transporter performance tracking across all commodities

Single SAP integration for all inbound GR posting

Activity Sensing for Each Commodity

The IAS (Intugine Activity Sensing) module uses IoT sensors to detect physical unloading activity regardless of material type. The sensor data signature of a bulk unloading event — physical displacement of cargo body, sustained activity consistent with material discharge — is similar across iron ore, coal, and limestone trucks.

One device, one algorithm, three commodities covered.

Gate Management Integration

The plant gate is the last control point. Without risk intelligence, it is a bottleneck — every truck queuing for manual checking slows TAT for all vehicles.

With risk scoring: only HIGH-scored trucks are directed to special sampling. LOW and MEDIUM risk trucks clear the gate on the standard queue. Gate TAT improves while security coverage on actual risk increases.

Weighbridge and LIMS Integration

Trip risk score visible at weighbridge terminal before the truck drives on. High-risk trips automatically flagged to LIMS for grade quality sampling alongside weight verification. SAP GR posting triggered on confirmed delivery.