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Food & Beverage

FSSAI Compliance & Food Traceability Solution

Every food business operator licensed by FSSAI must trace one step back and one step forward, and withdraw an affected lot without guesswork. We build the FSSAI traceability software that does it, from goods receipt to despatch, engineered around your plant, your SKUs and the ERP you already run.

One-Up One-Down, Proven

Supplier lot to finished pack to distributor, linked as a single queryable chain rather than three registers.

Digital Batch Records

Process parameters, QC results and operator sign-offs captured at the step, not copied into a file later.

FoSCoS and Audit Documentation

Licence details, product approvals and audit evidence held against every batch and every SKU.

Our FSSAI Compliance & Food Traceability Solution

Four connected modules covering incoming material, production genealogy, finished goods identification and compliance reporting, delivered as one engineered system with the coding and scanning hardware it needs.

1. Supplier & Incoming Material Traceability
Traceability breaks at the gate more often than anywhere else. We capture supplier lot identity at goods receipt and hold it against QC release, so no unapproved material reaches a batch.

Key Capabilities:

Supplier lot, invoice and vehicle capture at GRN weighbridge
Incoming QC sampling, retention samples and release or quarantine status
Supplier approval, FSSAI licence validity and COA document verification
FEFO issue control blocking expired or quarantined lots automatically
2. In-Process Batch Genealogy & Rework
Blending, splitting, rework and repacking all break a simple lot chain. We model each of these as explicit events so any finished pack resolves back to every raw lot that entered it.

Key Capabilities:

Batch card, recipe version and consumption recorded per production order
Blend and split genealogy for many-to-many material relationships
Rework and reprocessing lots linked to their original parent batches
CCP, cooking and chilling parameters logged from plant instruments
3. Finished Goods Coding & Despatch
A lot code that only exists on a printed carton is not traceable. We code and verify packs, cases and pallets, and link every despatch to the distributor receiving it.

Key Capabilities:

Lot, batch and expiry coding on pack, case and shipper
GS1-128 and QR coding with camera verification before palletisation
Case to pallet aggregation captured on line at production speed
Despatch linked to invoice, e-way bill, vehicle and distributor code
4. FSSAI Compliance & Audit Reporting
The QA head needs evidence assembled, not scattered across files. Batch records, test results, labelling data and trace queries are held in one audit-ready structure with defined retention and controlled access.

Key Capabilities:

Trace-back and trace-forward reports generated from a single lot query
Labelling data checked against FSSAI Labelling and Display Regulations
Schedule 4 hygiene checklists and internal audit records per shift
Retention rules, electronic sign-off and full change-history logging

Technologies That Power Our Solutions

Hardware and software chosen for wet, dusty, hot and cold plant conditions, after a site walkthrough rather than from a catalogue.

Industrial Coding & Vision Systems
Continuous inkjet, thermal transfer and laser coders with cameras confirming the lot and expiry are legible before the pack is cased.

Applications:

Expiry printing Code verification Label check Reject actuation
Plant Instrument & PLC Integration
Weighers, metal detectors, checkweighers, temperature probes and PLCs feed the batch record directly, removing transcription error from CCP evidence.

Applications:

CCP capture Weight reconciliation Detector logs Chill cycles
Rugged Scanning & Mobile Capture
IP-rated handhelds and washdown-tolerant terminals for stores, production floor and despatch bay, specified to work reliably with wet, gloved hands.

Applications:

GRN scanning Material issue Pallet build Despatch loading
Traceability Data Platform
The event store holding lot genealogy, batch records and despatch links, deployed on-premise or on private cloud per your IT policy.

Applications:

Genealogy queries Batch storage ERP synchronisation Audit archives

Industry Success Stories

Representative outcomes from food processing deployments. Figures are indicative ranges for this solution type and must be confirmed against your own baseline before publication.

Packaged Food & Snack Processors
Multi-SKU plants running blending, frying and packing lines with high raw material variety and short shelf life.

Results Achieved:

Trace-back query time reduced from days to under an hour
55-70% reduction in manual batch documentation effort
Batch record gaps found during audits materially reduced
Spice, Flour & Ingredient Millers
Grinding and milling units where one raw lot is split across many output batches and customers.

Results Achieved:

Split-lot genealogy captured across all output batches
40-60% faster closure of customer complaint investigations
Supplier lot capture at GRN raised to near-full coverage
Beverage & Bottling Operations
High-speed filling lines where coding, aggregation and despatch linking must run without slowing output.

Results Achieved:

Line speed impact held within agreed limits during pilot
30-50% reduction in despatch and distributor mismatch queries
Mock recall completed inside the target window

Key Performance Indicators

The measures a QA head and a plant head agree with us before deployment, then track from the dashboard once the system is live.

Trace-Back Query Time
Time to resolve a finished pack lot code to every raw material lot that contributed to it.

Target: Under 30 minutes

How we get there: Achieved because genealogy is recorded as events at the step rather than reconstructed afterwards.
Batch Record Completeness
Share of batches closed with every mandatory process, QC and sign-off field captured.

Target: >99%

How we get there: Enforced by mandatory-field logic and instrument feeds rather than post-shift data entry.
Lot Code Read Rate
Share of printed lot and expiry codes verified as legible by the vision system at line speed.

Target: >99.5%

How we get there: Engineered through coder selection, substrate trials and lighting design during the pilot.
Mock Recall Reconciliation
Quantity accounted for as produced, despatched, held and recovered during a mock recall drill.

Target: 100% accounted

How we get there: Driven by despatch-level distributor linking rather than approximation from the sales ledger.

How We Deliver

A staged sequence that proves the design on one line before it touches the whole plant.

Step 1: Requirement Study & Process Mapping

We walk the plant from gate to despatch bay, document every blend, split and rework point, and record the FSSAI obligations applying to your licence category.

Step 2: Solution Design & Coding Strategy

Lot code structure, genealogy model, hardware bill of materials and ERP integration points are documented and signed off before any procurement starts.

Step 3: Pilot on One Production Line

One line and its feeding stores run live against agreed acceptance criteria, including a timed mock recall, so performance is proven on your own product.

Step 4: Rollout, Validation & Support

Remaining lines and stores are commissioned, QA and production teams trained, audit documentation handed over and the system moves into an agreed AMC.

Why Choose Our FSSAI Compliance & Food Traceability Solution?

Why food processors choose an engineered traceability system over a food safety module bolted onto an ERP.

Built Around Real Plant Flow
Blending, rework and repacking are where generic traceability modules quietly fail. We model them explicitly because that is where your recall exposure actually sits.
Hardware Responsibility Is Included
Coders, cameras, scanners and probes are supplied, installed and integrated by us, and we own read-rate and print-quality performance in your washdown environment.
Regulation Named, Not Implied
FSSAI licensing conditions, FoSCoS documentation, labelling amendments and recall guidelines are engineered in as specific, named requirements rather than a vague compliance promise.
One Team After Go-Live
Software, hardware and integration are maintained by the same engineering team under a documented support arrangement with agreed response times and preventive maintenance.

Make Your Plant Audit-Ready and Recall-Ready

Book a requirement discussion with our engineering team. We will walk your process from goods receipt to despatch, then come back with a scoped approach, a hardware outline, a pilot line proposal and an indicative timeline.

FAQ – Frequently Asked Questions

FSSAI traceability software is a system that lets a food business operator identify, for any batch it produces, which supplier lots went into it and which customers received it. That one-up one-down capability, with recall readiness, captures supplier lot identity at goods receipt, records genealogy through blending, processing and packing, codes the finished pack, and links each despatch to the distributor.

It is built for you. We are a custom solution development and systems integration company, not a SaaS vendor. Every engagement starts with a requirement study of your plant and licence category, and the system is engineered to that.

Yes. Coding equipment, vision cameras, rugged handhelds, label printers and weighing interfaces are scoped, supplied, installed and integrated as part of the project. We take responsibility for code legibility and read rates on your line.

Yes. We integrate with SAP, Oracle, Microsoft Dynamics, Tally and in-house systems for purchase orders, GRN, production orders, stock and despatch. Where no standard connector exists, we build the interface within the project scope.

Each is modelled as an explicit genealogy event. A blend records every contributing lot with its consumed quantity, a split records each child batch, and rework links a reprocessed lot back to its parent batch.

Yes. Label content for each SKU is held as controlled master data and checked against the declarations required by the FSSAI Labelling and Display Regulations, including allergen and nutritional fields.

Yes. On-premise, private cloud and hybrid deployments are supported. Many processors prefer a plant-level server so line capture continues during an internet outage, synchronising to a central instance once connectivity returns.

A single-line pilot covering stores, production and despatch is usually live within eight to fourteen weeks of requirement sign-off. Plant-wide rollout follows in phases and depends on line count, SKU complexity, hardware lead times and ERP integration depth.

Yes, that is one of its main purposes. Batch records, QC results, supplier approvals, hygiene checklists and trace reports are retrievable against a lot code or date range, so evidence comes from the system rather than from files.

The system moves into an agreed support arrangement covering defined response times by severity, preventive maintenance of coding and scanning hardware, updates when FSSAI formats or labelling rules change, and enhancement requests.