Cold Chain Monitoring

Prevent Spoilage Before It Happens—Real-Time Monitoring, Instant Alerts

The Challenge

Temperature-sensitive products—food, pharmaceuticals, biologics—are the backbone of modern supply chains. But a single temperature break can mean product loss, regulatory violations, and customer trust erosion.

  • Product spoilage from temperature breaks you didn't detect in time
  • Regulatory violations leading to financial penalties and compliance risks
  • Manual monitoring that's labor-intensive, error-prone, and always reactive
  • No real-time alerts when problems occur—you discover issues after the damage is done
  • Distributed operations across 100s of warehouses with no central visibility
  • Transport gaps where temperature integrity is unknown during transit
  • Repeat offenders (locations, routes, equipment) that you can't identify without trend data

You need real-time monitoring with instant alerts—not just data logging.

The IoTReady Cold Chain Solution

From warehouse to doorstep—monitor every temperature zone in real-time with automated alerts and predictive analytics

1. Real-Time Monitoring

Continuous temperature and humidity tracking across all storage zones, refrigeration units, and transport vehicles. See live data from 100s of locations on one dashboard.

2. Instant Alerts

Immediate notifications for temperature deviations, door-open events, and equipment failures. Staff receive alerts on mobile devices and via in-store buzzers—act before spoilage occurs.

3. Predictive Analytics

Historical trend analysis identifies repeat offenders (locations, equipment, routes) and patterns that indicate impending failures. Prevent problems before they happen.

4. Mobile Workflows

Staff use mobile app to dispatch shipments, assign sensors to specific trips, log manual readings, and acknowledge alerts. Streamlined workflows improve response efficiency.

5. Compliance Ready

Automated reporting for regulatory requirements (FSSAI, FDA, ISO). Complete audit trail with timestamped temperature records and deviation logs.

6. Transport Monitoring

Track temperature during transit with offline-capable sensors. Accurate timestamps even without connectivity. Full visibility from warehouse to customer doorstep.

Smart IoT Technology

Industrial-grade sensors designed for the demanding cold chain environment

Why You Need Dedicated Cold Chain Sensors

Most freezers and chillers have built-in sensors and displays—but these measure the temperature of the AC unit, not where your inventory is stored. What matters is the actual temperature at shelf level where products sit. IoTReady sensors are placed directly in storage zones to measure the temperature your products experience, not what the refrigeration unit thinks it's delivering.

Sensor Options: Wireless & Wired

🔷 Wireless BLE Sensors (Battery-Powered)

Range: 50 meters from gateway

Battery Life: 2 years on single battery

Operating Range: -40°C to +70°C

Build: Waterproof, dustproof (IP67), industrial-grade

Sensors per Gateway: Multiple sensors (typically 10-20) per gateway

Best for: Easy deployment, no wiring, multiple zones per location

Offline Capability: 60,000 records stored locally per sensor with accurate timestamps—syncs automatically when connectivity restored

🔌 Wired DS1820 Sensors

Range: Up to 30 meters from gateway via cable

Power: Powered via cable (no batteries to replace)

Operating Range: -55°C to +125°C

Build: Industrial-grade, hermetically sealed

Sensors per Gateway: Multiple sensors (typically 10-30) daisy-chained per gateway

Best for: Permanent installations, high-reliability requirements, locations with existing cable infrastructure

Benefits: No battery maintenance, reliable power, suitable for critical applications requiring maximum uptime

🚪 Door Open/Close Sensors

Purpose: Detect unauthorized door openings or doors left open

Alerts: Instant notification when cold room door exceeds open-time threshold

Integration: Correlate door events with temperature spikes to identify root causes

Why It Matters: Door-left-open incidents are a leading cause of temperature excursions. Immediate alerts prevent spoilage.

📺 In-Store Display with Buzzer

Purpose: Local visual and audible alerts for warehouse/store staff

Display: Real-time temperature readings for all monitored zones

Alerts: Built-in buzzer for immediate attention when deviations occur

Benefits: Staff don't need to check mobile apps—alerts are visible and audible at point of action. Immediate awareness leads to faster response.

Flexible Connectivity Options

Connect gateways to the cloud via the best available network option at each location

📶 WiFi (Primary)

Easy configuration via mobile app or web interface. Connect to existing facility WiFi networks. Automatic reconnection on network interruptions.

🔌 Ethernet

Wired LAN connection where available. Most reliable option for permanent installations. POE (Power over Ethernet) support available.

📱 4G Cellular (with M2M SIM)

IoTReady holds an M2M SIM license from the Government of India. We partner with Airtel, Reliance Jio, and Vodafone—select the best carrier network for each location. Ideal for remote sites without WiFi/Ethernet or as backup connectivity.

🔄 Automatic Failover

Gateway intelligently switches between available connections (WiFi → Ethernet → 4G) to ensure continuous monitoring even during network outages.

Central Monitoring Dashboard

Multi-Location View: Monitor 100s of warehouses from single dashboard

Real-Time Data: Live temperature readings, alert status, historical trends

Advanced Analytics: Identify patterns, repeat offenders, equipment degradation

Custom Scripting: SQL and Python support for custom reports and integrations

Platform Features

📱 Mobile App for Dispatch & Logging

Staff use mobile app to:

  • Record vehicle, trip, and destination details before dispatch
  • Assign sensor IDs to specific shipments
  • Log manual temperature readings as backup
  • Acknowledge alerts and log corrective actions

📊 Advanced Analytics & Reporting

Go beyond real-time monitoring:

  • Historical trend analysis to identify patterns
  • Repeat offender reports (locations, equipment, routes)
  • Compliance reports for audits (FSSAI, FDA, ISO)
  • Custom reports via SQL/Python scripting

🔔 Customizable Alert Rules

Configure alerts for your specific needs:

  • Temperature thresholds per zone or product type
  • Door-open duration limits
  • Multi-level escalation (staff → supervisor → manager)
  • Alert delivery via mobile app, SMS, email, or in-store buzzer

🔗 ERP & Quality System Integration

Seamless integration with existing systems:

  • Push temperature deviation events to quality control systems
  • Link temperature data to batch/lot numbers
  • Trigger automated quality holds on affected inventory
  • Export compliance reports to ERP for audit trail

Cold Chain on the Move: Transport Monitoring

Temperature integrity doesn't end at the warehouse. Monitor temperature during transport with full offline capability.

Before Dispatch

Staff use mobile app to record:

  • Vehicle ID and driver details
  • Trip route and destination
  • Assign sensor ID to shipment
  • Expected delivery time

During Transit

Sensors monitor temperature continuously:

  • 60,000 offline records per sensor
  • Accurate timestamps even without connectivity
  • Auto-sync when network available
  • Real-time alerts if online connectivity available

After Delivery

Complete trip report generated:

  • Full temperature history from dispatch to delivery
  • Any deviations flagged with timestamps
  • Link to customer order for quality assurance
  • Audit-ready compliance documentation

Use Cases Across Industries

🏪 Multi-Store Retail Chains

Challenge: Hundreds of retail outlets with cold storage, no central visibility

Solution: Centrally monitor all locations from single dashboard. Instant alerts to store staff via in-store display and mobile app. Identify repeat offender locations for corrective action.

Impact: Prevent spoilage across distributed operations, ensure brand consistency

📦 E-commerce & Quick Commerce

Challenge: Warehouse-to-doorstep cold chain integrity, last-mile temperature breaks

Solution: Monitor temperature from warehouse through fulfillment, transport, and delivery. Offline-capable sensors ensure data even in connectivity-challenged routes.

Impact: Customer trust through guaranteed quality, reduced returns and complaints

Customer: Flipkart

💊 Pharmaceuticals & Biologics

Challenge: Strict regulatory requirements for temperature-sensitive drugs, vaccines, biologics

Solution: Auditable temperature monitoring with complete compliance reporting. Automated alerts prevent temperature excursions. Full audit trail for regulatory inspections.

Impact: Regulatory compliance, patient safety, reduced product loss

🍽️ Food Processing & Distribution

Challenge: FSSAI compliance, multi-stage cold chain (processing → storage → distribution → retail)

Solution: End-to-end temperature monitoring from production facility through cold storage, transport, and final delivery. Integration with quality control systems.

Impact: FSSAI compliance, food safety assurance, reduced wastage

Customer Success: Flipkart Cold Chain

Ensuring Quality Across Distributed Cold Chain Operations

Challenge

Flipkart operates cold chain logistics across 100s of warehouses for grocery and perishables. Manual temperature monitoring couldn't provide real-time visibility or prevent spoilage proactively.

Solution

IoTReady deployed temperature and door sensors across all cold storage facilities. Real-time monitoring with instant alerts for temperature and door deviations. Trend analytics to identify repeat offender locations.

Technologies

  • BLE temperature & humidity sensors
  • Door open/close sensors
  • Central monitoring dashboard
  • Real-time alert system

Results

  • Quality assurance through proactive spoilage prevention
  • Real-time alerts for temperature and door deviations
  • Trend analytics identify repeat offenders for corrective action
  • Compliance documentation for quality audits

Read Full Case Study →

Why Choose IoTReady for Cold Chain Monitoring?

⚡ Quick Setup

Start monitoring in minutes, not weeks. BLE sensors require no wiring or installation—just place, pair, and go. No infrastructure changes needed.

📊 Intuitive Dashboard

See all your locations at a glance. Color-coded status indicators, historical trends, and drill-down details. No training required—clear insights instantly.

✅ Compliance Ready

Automated reporting for FSSAI, FDA, ISO, and other regulatory requirements. Complete audit trail with timestamped records and deviation logs.

💰 Cost-Effective

2-year battery life means low maintenance. 60,000 offline records per sensor means no data loss. Scalable pricing—start small, grow as needed.

🔧 Highly Customizable

Configure alert thresholds, escalation rules, and reporting to match your operations. SQL/Python scripting support for custom integrations and workflows.

🏆 Proven at Scale

Deployed across 1,500+ warehouses in 100+ cities across India. Trusted by Flipkart, BigBasket, Zomato, and other leading companies.

How It Works: System Architecture

graph LR
    subgraph Warehouse["Warehouse / Store"]
        S1[BLE Temp Sensors
or
Wired DS1820 Sensors] S2[Door Sensors] D[In-Store Display + Buzzer] G[Gateway
10-30 sensors per gateway] end subgraph Connectivity["Connectivity Options"] WIFI[WiFi] ETH[Ethernet] G4[4G M2M SIM
Airtel/Jio/Vodafone] end subgraph Transport["Transport Vehicle"] S3[Offline Temp Sensor] M[Mobile App] end subgraph Cloud["IoTReady Cloud Platform"] DB[(Real-Time Database)] AN[Analytics Engine] AL[Alert System] end subgraph Users["Users & Systems"] DASH[Central Dashboard] APP[Mobile App Alerts] ERP[ERP Integration] end S1 --> G S2 --> G G --> D G --> WIFI G --> ETH G --> G4 WIFI --> DB ETH --> DB G4 --> DB S3 -.Offline Storage.-> S3 S3 -->|Sync when online| M M --> DB DB --> AN AN --> AL AL --> D AL --> APP DB --> DASH AN --> DASH DB --> ERP style S1 fill:#0ea5e9 style S2 fill:#0ea5e9 style S3 fill:#0ea5e9 style D fill:#f59e0b style G fill:#6366f1 style WIFI fill:#10b981 style ETH fill:#10b981 style G4 fill:#10b981 style DB fill:#16a34a style AL fill:#dc2626

Sensor Layer: Wireless BLE (battery-powered) or Wired DS1820 sensors—multiple sensors per gateway (10-30 depending on type)

Edge Layer: Gateway with in-store display provides immediate local visibility and alerts

Connectivity: WiFi, Ethernet, or 4G cellular with M2M SIM (Airtel/Jio/Vodafone)—automatic failover between options

Cloud Platform: Real-time data processing, analytics, and multi-channel alerting

User Interface: Central dashboard for managers, mobile app for staff, ERP integration for compliance

Frequently Asked Questions

How long does it take to deploy cold chain monitoring?
For the first location: 1-2 weeks to install sensors and gateways, configure alert thresholds, integrate with quality systems, and train staff. For additional sites: ~15 minutes per sensor/gateway using the proven configuration. Flipkart deployed across 100s of locations—the first site establishes the template, then subsequent deployments are rapid.
Do we need special infrastructure or wiring?
We have 2 kinds of sensors: (1) BLE sensors—wireless, battery-powered (2-year battery life), no wiring needed. Perfect for most deployments. (2) Wired sensors—for shielded locations or where higher reliability is required. Both BLE beacons and gateways have offline capabilities and sync data when network is available. Gateways connect via existing WiFi, Ethernet, or 4G cellular.
What if our cold rooms don't have WiFi?
We provide 4G cellular connectivity with M2M SIM cards (Airtel, Jio, Vodafone). IoTReady holds an M2M SIM license from Government of India—we select the best carrier for each location. Gateways can also use Ethernet. Automatic failover between WiFi, Ethernet, and 4G ensures continuous monitoring.
How many sensors do we need per cold room?
Typically 1-3 sensors per cold room depending on size. Small rooms (10x10 ft): 1 sensor. Medium rooms (20x20 ft): 2 sensors. Large warehouses: 3+ sensors at different zones. We support up to 50m range per sensor with up to 20 sensors per gateway. Sensors placed at product storage level (not AC unit level) to measure actual product temperature.
Can we monitor temperature during transport?
Yes. Offline-capable sensors with 60,000 record storage continue logging even without connectivity. Staff use mobile app to assign sensor to trip, record vehicle details, and destination. Sensor syncs data when back online. Complete temperature history from warehouse to delivery for full cold chain integrity.
What's the typical ROI for cold chain monitoring?
Most customers see significant spoilage reduction from catching temperature breaks early, faster response times (minutes vs hours) with instant alerts, and compliance readiness for FSSAI/FDA audits. Flipkart: proactive spoilage prevention across 100s of locations. ROI from reduced product loss alone typically justifies investment within 3-6 months.
How do alerts work?
Multi-channel instant alerts: mobile app notifications, SMS, email, and in-store buzzer/display for local staff. Configurable thresholds per zone and product type. Multi-level escalation (staff → supervisor → manager) if not acknowledged. Door-open alerts trigger if cold room door left open beyond threshold.
Can we generate compliance reports for audits?
Yes. Automated reporting for FSSAI, FDA, ISO requirements. Complete audit trail with timestamped temperature records, deviation logs, and corrective action records. Export reports as PDF or Excel. All data immutable with tamper-proof timestamps for regulatory compliance.
What if sensors lose connectivity?
Offline mode with local storage—sensors continue logging with accurate timestamps even without network. BLE sensors: 60,000 records stored locally. Auto-sync when connectivity restored. No data loss. Alert if gateway offline for extended period.
How scalable is the platform?
Handles 1000s of locations from single dashboard. Currently deployed at 1500+ warehouses and stores. Flipkart: 100s of cold storage facilities monitored centrally. BigBasket: 670+ locations. Zomato: fresh produce across fulfillment centers. Central dashboards aggregate data across all sites—perfect for multi-location retail chains and distribution networks.

Ready to Secure Your Cold Chain?

Prevent spoilage before it happens with real-time monitoring and instant alerts across all your facilities

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