Zventory’s AI-powered platform enabled a food & beverage processing unit to achieve complete batch traceability, tighter quality control, accurate expiry tracking, and smoother production coordination, ensuring compliance and efficient pan-India distribution.

Enhancing Quality Control, Batch Traceability & Production Efficiency Using the Zventory (AI Powered) Industry: Food & Beverage Manufacturing (Snacks, Spices, Beverages, Packaged Foods) Company Size: 150+ workforce, pan-India distribution Modules Used: Inventory, Production, Purchase, QA/QC, Sales, Dispatch, DMS, HR Key Challenges: Batch management, expiry tracking, quality control, purchase planning, production coordination

Background

A growing food processing company manufacturing snacks, spices, herbal beverages, and packaged ready-to-eat items was struggling to maintain operational discipline as demand increased.

• Strict batch-wise stock tracking
• Expiry and FIFO management
• Quality testing documentation
• Timely production cycles
• Consistent dispatch planning

Their legacy system only recorded basic stock quantities without linking batches, quality checks, or expiry timelines. This resulted in wastage, compliance risks, production delays, and inaccurate planning. To overcome these challenges, the company adopted the Zventory (AI Powered), transforming their end-to-end operations.

The Challenges

1. Lack of Proper Batch Management

Batch tracking is critical in the food industry for traceability, quality assurance, recall management, and consistency. However:

• Raw material batches were difficult to track
• Incorrect batch mixing occurred during production
• Finished goods traceability was limited
• Audit compliance became risky

2. Expiry Tracking & FIFO Not Followed

Materials such as spices, oils, additives, and packaging had defined shelf lives, but:

• Expired batches mixed with fresh stock
• Last-minute disposal increased wastage
• No visibility of near-expiry materials

3. Inefficient Production Planning

The production team lacked real-time visibility, leading to:

• Production halts due to material shortages
• Over-ordering of raw materials
• Delayed dispatch schedules

4. Quality Control Documentation Issues

QC records were manually maintained, causing:

• Misplaced QC reports
• Delayed batch approvals
• No linkage between QC status and stock movement
• Difficulty during audits

5. Reactive Purchase Planning

The purchase team faced challenges due to:

• Lack of real-time consumption data
• No visibility of upcoming production needs
• Absence of AI-based forecasting

The Solution Implemented

The Zventory (AI Powered) digitized inventory, production, QC, purchase, and dispatch into one unified platform. ✔ Batch-wise Inventory & Traceability

• Batch number assignment
• Manufacturing & expiry dates
• Supplier-wise batch tracking
• Complete traceability from raw material → production → finished goods → dispatch

✔ Real-Time Production Monitoring

• Start, running, pending, and completed production tracking
• Batch-wise material consumption
• Output quantity visibility
• Live production status for management

✔ Auto Purchase Indent & AI Forecasting

• Automatic purchase indents at reorder levels
• Material requirement based on production plans
• AI-driven demand forecasting
• Reduced emergency procurement

✔ Quality Control Integration

• Digitized QC forms
• Parameter-wise testing records
• Batch-wise QC approval or rejection
• Only approved stock moved to production or dispatch

✔ Dispatch & Logistics Management

• Batch-wise finished goods tracking
• Warehouse and customer-level visibility
• Vehicle and logistics integration

✔ Document Management System for Compliance

• FSSAI documentation
• HACCP records
• SOPs and process sheets
• Packaging specifications
• QC certificates

The Results

1. 60% Improvement in Batch Accuracy

2. 70% Reduction in Expiry-Related Wastage

3. Production Delays Reduced by 40%

4. 100% Traceable QC Approvals

5. Significant Improvement in Purchase Efficiency

6. Faster Dispatch with Zero Stock Mismatch

Conclusion

Zventory (AI Powered) brought discipline, transparency, and speed to the food processing company’s operations. By digitizing batch tracking, QC processes, expiry management, and production planning, the company ensured compliance, reduced wastage, improved profitability, and scaled confidently across markets.