Microtrol India

Paperless Workflow for Gamma Irradiation Sterilisation

Pharmaceuticals—Sterilisation Services

Industry

Pharmaceutical Sterilisation Services

Scale

600 boxes per day, 24x7 operations with 3 shift managers

Solutions Deployed

Operations Traceability Platform, QR Tracking, Automated Weighment, Tally Integration

The Challenge

Microtrol India provides sterilisation services including Gamma Radiation, Ethyl Oxide, Electron Beam, and Steam Sterilisation to pharmaceutical and medical device manufacturers. Their gamma irradiation plant faced multiple operational challenges:

  • Paper-heavy workflows—9+ documents required per consignment, manually filled and stored for 5-6 years for audit compliance
  • Multiple data entry points—same information manually entered in registers, Tally software, and multiple forms leading to errors
  • Document tracking difficulties—tracking material and document movement during overnight turnarounds across 3 shifts was challenging
  • Manual weighment recording—prone to errors and time-consuming for 600 boxes per day
  • Slow document retrieval—finding historical records for customer audits (spanning 5-6 years) was time-consuming
  • No real-time visibility—customers and management had no real-time visibility into consignment status
  • Quality department bottlenecks—dosimeter analysis and certificate preparation delayed dispatch
  • Regulatory compliance risk—pharmaceutical customers routinely conduct physical site audits requiring complete traceability

With pharmaceutical customers demanding complete traceability and audit-proof documentation, manual paper-based processes created gaps, errors, and inefficiencies that risked compliance and customer satisfaction.

The IoTReady Solution

Comprehensive paperless workflow for gamma irradiation operations

1. QR Code-Based Batch Tracking

Unique identification for every consignment:

  • Unique QR code per batch—automatically generated and printed on labels for each box
  • End-to-end traceability—track from customer request receipt to certificate issuance
  • Mobile scanning—operators scan QR codes at each workflow step using rugged tablets
  • Instant document retrieval—scan any box to instantly access all related documents and processing history
  • Audit trail—complete timestamped history of every scan and workflow transition

2. Automated Weighment Integration

Eliminate manual weight recording errors:

  • Weighing data loggers—automatic capture of incoming and outgoing weights
  • Real-time weight data—weights automatically recorded in consignment forms and invoices
  • Material accountability—automated verification of no material loss during processing
  • Customer confidence—accurate weight records build trust with pharmaceutical customers

3. Mobile Workflow Management

Paperless operations with rugged tablets:

  • Rugged tablets (Chainway P80)—deployed for operators in production, quality, and admin teams
  • Digital forms—replace 9+ paper documents with mobile form-based workflows
  • Real-time updates—instant status updates visible to all departments
  • Photo documentation—capture dosimeter readings and product labels digitally
  • Operator authentication—digital signatures and timestamps for compliance
  • Offline capability—works even during network outages, syncs when reconnected

4. Workflow Step Tracking

Complete visibility into process completion:

  • 7-step workflow—from gamma request form submission to certificate and invoice issuance
  • Real-time status updates—know exactly which step each consignment is in
  • Bottleneck identification—identify delays in quality evaluation or admin processing
  • Automatic notifications—alert next department when consignment is ready for them
  • Priority management—digitally manage processing priorities communicated by customers

5. Tally ERP Integration

Automated financial documentation:

  • Automatic invoice generation—data flows from workflows directly into Tally
  • Eliminate duplicate entry—no more manual entry of same information in multiple systems
  • Faster billing cycle—reduce time from processing completion to invoice issuance
  • Customer data sync—company details, GST numbers, and contact info automatically populated

6. Digital Document Management

Audit-proof digital records:

  • PDF templates—standardized digital templates for all certificates and reports
  • Electronic storage—eliminate physical document binding and storage requirements
  • Instant retrieval—search and access any document by QR code, customer name, or date range
  • 5-6 year retention—digital archival meets pharmaceutical audit requirements
  • Customer portal—customers can access their certificates and invoices online

Business Impact

90%

Reduction in Paper Usage

9+ documents per consignment now digital

Zero

Manual Weight Recording Errors

Automated weighment integration

Real-Time

Consignment Visibility

24x7 tracking across all shifts

Instant

Document Retrieval

vs. hours searching physical archives

50%

Faster Billing Cycle

Automated Tally integration

100%

Audit Trail Completeness

Every transaction timestamped

Technologies Deployed

Operations Traceability Platform (OTP)

Low-code workflow management platform with real-time operator feedback and issue management

QR Code Scanning

Unique batch identification with mobile scanning at every workflow step

Rugged Tablets (Chainway P80)

Industrial-grade tablets for 24x7 operations with barcode scanning capability

Weighing Data Logger

Automated weight capture from weighing scales with real-time data integration

Tally Integration

Real-time data sync with Tally for automated invoice generation and accounting

Digital Forms & Templates

Mobile-first forms replacing paper documents with PDF generation for certificates

Rapid Implementation

From site visit to full rollout in just 2 months

Phase 1: Specification (1 week)

  • Functional specification review
  • Technical specification finalization
  • Workflow confirmation with operations team

Phase 2: Development (3 weeks)

  • Workflow implementation and validation
  • Printer and weighing scale integration
  • Tally API integration
  • Pilot testing with real batches

Phase 3: Rollout (5 weeks)

  • Customer-by-customer rollout
  • Batch-wise transition from paper to digital
  • Operator training on tablets

Ongoing: Support

  • 4-hour response time (9am-6pm)
  • 99.5% uptime SLA
  • Continuous workflow optimization

Why Microtrol Chose IoTReady

Low-Code Adaptability

Operations Traceability Platform allows Microtrol to adapt workflows themselves as SOPs evolve—no waiting for vendor changes.

Rapid Deployment

Go-live in less than 24 hours for new workflows. Pilot to production in weeks, not months.

Hardware + Software Integration

IoTReady designs and manufactures weighing data loggers and integration hardware—no third-party integration headaches.

Pharmaceutical Compliance Experience

Built-in audit trails, electronic signatures, and document management meet stringent pharmaceutical audit requirements.

Expanding to Other Sterilisation Processes

With gamma irradiation workflows delivering proven results, Microtrol is exploring similar digital transformation for other processes

Ethylene Oxide Sterilisation

Apply the same paperless workflow to ETO sterilisation with automated aeration tracking

Electron Beam Sterilisation

Track E-beam processing with real-time dosage monitoring and certificate generation

Steam Sterilisation

Monitor autoclave cycles with temperature and pressure data logging for complete traceability

Customer Portal

Enable customers to track consignments in real-time, access certificates, and schedule audits online

Related Solutions

Batch Traceability

Complete chain of custody from raw materials to finished goods with audit-proof records.

ERP Integration

Real-time data sync with Tally, SAP, Oracle, or any ERP system.

Sterilisation or Contract Manufacturing?

See how our Operations Traceability Platform can bring paperless workflows to your plant