Inovace Technologies deployed its Real-Time Visibility & Analytics (RTVA) and IOMS weight-counting system at Unilever Bangladesh. By verifying ingredient ratios and pack weights in real time instead of after batch analysis, the plant cut excess giveaway (EGA) and saves approximately BDT 15 lakh per day. The project was showcased at Hindustan Unilever as an iconic deployment.
The problem
On high-speed FMCG lines (Surf Excel, Rin, Wheel, Vim), tiny per-pack overfills and ingredient-ratio drift are invisible day-to-day and enormous at scale. Quality checks were manual and after-the-fact. By the time a drift was found, tons of product had already shipped heavy.
What we built
- Sensors and digital weight-counting at packing zones, feeding live dashboards per line (batch status, packing zone, quality status, dispatch).
- Automated quality checks: ingredient ratios verified against predefined thresholds, continuously.
- Real-time defect detection with instant alerts, with no waiting for manual analysis.
- Root-cause analysis across SKUs, stations and shifts, so waste sources get named, not guessed.
The result
Excess-giveaway percentage down, defective packages eliminated before dispatch, compliance guaranteed against standard, and approximately BDT 15 lakh per day saved. Showcased at Hindustan Unilever as an iconic project.
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