End-to-End Biomass Automation: Unified Gate, ERP & Farmer Management System
A leading energy company is driving India’s transition to sustainable baseload power through innovative decarbonization solutions. As one of the country’s fastest-growing energy companies, the organization specializes in delivering clean, affordable, and environmentally responsible energy projects designed to meet India’s growing power demands. As India's leading biomass power producer, they transformed their industrial processes to address three critical challenges in the biomass supply chain:
As India's leading biomass power producer, they transformed their industrial processes to address three critical challenges in the biomass supply chain:
- Inefficient vehicle management across diverse entry types (trucks, tractors, bullock carts)
- Material flow inconsistencies causing FIFO violations
- Disconnected systems leading to operational blind spots
Our solution integrates ERP-connected smart gates with farmer-friendly interfaces and real-time biomass tracking - creating India's first truly sustainable biomass management ecosystem.
The Operational Challenges
1. Chaotic Gate Management
- 45-minute average wait times for mixed vehicle entry (trucks/tractors/bullock carts)
- 25% unauthorized entries due to manual verification
- No linkage between gate data and ERP systems
2. Fuel & Biomass Integrity Issues
- 18-22% fuel pilferage at unmanned locations
- 35% FIFO non-compliance in biomass processing
- Manual moisture checks causing 12% quality variations
3. Farmer Partnership Pain Points
- Cash-based transactions creating reconciliation delays
- No visibility for farmers on biomass quality metrics
- Payment disputes affecting supplier trust
The Smart Automation Solution
1. Unified Gate Ecosystem
- Multi-mode authentication (QR for trucks)
- ERP-integrated weighbridge with auto-FIFO tagging
- Bullock cart registration via simplified kiosks
2. Intelligent Fuel & Biomass Control
- IoT dispensers with ERP-approved fuel release
- AI-powered moisture monitoring at entry points
- Automated quality-based sorting for optimal processing
3. Transparent Farmer Engagement
- Real-time digital slips with weight/quality/payment details
- Farmer portal for transaction history and payments
- SMS alerts for load approval status
4. Centralized Plant Intelligence
- SAP-integrated dashboard for end-to-end visibility
- Auto-generated purchase orders based on stock levels
- Predictive maintenance alerts for equipment
Results & Impact
Operational Efficiency
- 68% faster gate processing
- 100% FIFO compliance achieved
- 22% reduction in fuel costs
Sustainability Gains
- 15% improvement in biomass quality
- 28% reduction in truck idle emissions
- 40% decrease in paper-based processes
Farmer Benefits
- 75% faster payments through digital systems
- Complete transparency on quality metrics
Conclusion
The organization has created a blueprint for renewable energy operations that harmonizes industrial efficiency with agricultural partnerships. By implementing ERP-connected smart gates, farmer-friendly interfaces, and AI-driven quality control, we've achieved:
- Unprecedented operational visibility
- Strengthened farmer relationships
- Enhanced biomass-to-energy conversion efficiency
Our system demonstrates how technology can drive both sustainability and inclusive growth in India's renewable energy sector.
