Industrial RFID
RFID solutions for Indian manufacturers and warehouses
An RFID solution identifies materials, pallets, containers and assets by radio, without line of sight, so receiving, storage, movement and dispatch are recorded automatically as items pass readers. In a plant or warehouse it replaces manual counts and barcode scans at high volume points, and it works only if tags, readers and the software are designed for the actual site.
Free scoping call. We start with one line, never change your machine logic, and you own the code and the data.
- material movements tracked a day, integrated steel plant
- 720,000+
- fewer dispatch errors with RFID and barcode dispatch
- 90%
- items an hour through RFID warehouse automation
- 16,800
Company reported project figures, not independently audited, not a promise for another plant. Samsung Business Insights: our RFID warehouse automation story (opens in a new tab). Forbes India Brand Connect (sponsored): founder profile (opens in a new tab).
Sound familiar?
- Stock takes shut the warehouse for days and still do not match the ERP.
- Wrong material reaches the wrong line or the wrong truck.
- Crates, trolleys or dies go missing and are bought again.
- An RFID vendor promised read rates the tags never achieved on your items.
Each of these is output, margin or time you have already paid for and are not getting back.
What you get
A site survey
Items, surfaces, volumes, read points and the current process.
Tag trials on your items
Before you buy tags in volume, on real surfaces and stacking.
One flow live
For example receiving to binning, with the ERP updated automatically.
Middleware you own
Filtering reads into business events, extendable to new read points.
What we have built
Our RFID warehouse automation processes 16,800 paint barrels an hour, and automated receiving, binning, consumption and returns reduced manual labour by 60 percent at several sites.
In an integrated steel plant in India, our material tracking covers warehouses, central stores and vendor yards: more than 720,000 material movements tracked per day, and a 90 percent reduction in dispatch errors after RFID and barcode based dispatch.
Figures are company reported from past projects. They are not independently audited benchmarks and are not a promise for another plant. Read the case studies.
How we work
What we build
We design and implement RFID solutions end to end: site survey, tag and reader selection with on site testing, middleware, warehouse and material tracking software, and integration with SAP or your ERP. We are a solution provider and integrator; we select hardware from established RFID manufacturers to suit the site.
How a project starts
- 1Site survey. Items, surfaces, volumes, read points and the current process.
- 2Tag trials. Candidate tags tested on real items in real conditions.
- 3Pilot one flow. For example receiving to binning, with ERP updated.
- 4Scale. Add read points and flows using the same middleware and data model.
How it works
Designing an RFID system that actually reads
| Decision | Options | Why it matters |
|---|---|---|
| Frequency | UHF for distance and bulk reads; HF or NFC for close, single reads | Sets range and behaviour near metal and liquid |
| Tag type | Labels, hard tags, on metal tags, high temperature tags | The tag must survive the item’s life and read on its surface |
| Read points | Fixed portals, conveyors, forklift mounted, handheld | Decides which moves are captured automatically |
| Data standard | GS1 EPC encoding or an internal scheme | Affects sharing with customers and suppliers |
| Integration | Middleware filters reads into events for WMS, MES, ERP | Raw reads are noise; events are business data |
Common failure points
- Tags selected from a catalogue and not tested on the real item, surface and stacking.
- Portal reads that also pick up tags in the adjacent lane or staging area.
- No rule for unread items, so errors slip through silently.
- Reads sent straight to the ERP without filtering, creating duplicate movements.
- A process that still depends on someone remembering to carry the handheld.
Background
Where RFID pays in manufacturing
- Warehouse receiving and dispatch: pallets and containers read at the dock door, checked against the order.
- Inventory management: cycle counts with a handheld in minutes rather than a stock take shutdown.
- Material tracking inside the plant: bins, trolleys and containers read at gates between areas.
- Material traceability: batches linked to tagged containers from receipt to consumption.
- Returnable assets: crates, cylinders, dies and tools that go missing.
- Vendor material management: incoming vendor material identified and synced to the ERP at the gate.
RFID or barcode
RFID reads many items at once, without line of sight, and can be read at a distance. Barcodes and QR codes are cheaper per item, universal and reliable when someone can point a scanner. RFID earns its cost where volume is high, labour for scanning is significant, or items move through fixed points like doors and gates.
When we are not the right choice
- Volumes are low and staff already handle each item: barcode or QR will be cheaper.
- You need tags only, with no process or software. A distributor will serve you better.
Common concerns, answered
Will this disrupt production?
No. We connect read only first, install during planned stops, and edge devices buffer data so a network problem never stops a machine. Nothing writes to a PLC without your controls team and a test.
Our machines are old. Do we need to replace them?
No. Old machines are the usual case. A running signal, a cycle signal or a current sensor on the motor is enough to start, without touching the machine program.
We tried a system before and nobody used it.
That is the most common failure, so we design with the operators and supervisors who will use it, start with one report they already fill in by hand, and only extend once they rely on it.
What about IT security?
Read only by default, a segmented OT network, and a review with your IT team before anything connects, following the ISA/IEC 62443 zone approach.
We will not replace SAP or Oracle. Do we have to?
No. We connect to the ERP you already run through its standard interfaces and add what the shop floor is missing. Your ERP stays the system of record.
Do your engineers understand a heavy industrial floor?
Our systems run in steel plants, warehouses and process lines. We start every project by walking the line with your operators and supervisors, and the first release is tested by them, not only by IT.
Are we locked in?
No. You own the source code and the data, documented, in your own repository. Another team can maintain it.
Frequently asked questions
How much does an RFID solution cost in India?
Cost depends on the number of tags, the tag type, the number of fixed read points and the software and integration scope. Tags for metal or high temperature cost more than labels. We give a costed design after a site survey and tag trial rather than a per tag list price.
Does RFID work on metal?
Yes, with on metal tags designed for it, and with read points tuned on site. Standard labels placed directly on metal usually read poorly, which is why tag trials on the real item are part of every design.
Can RFID integrate with SAP?
Yes. Middleware turns filtered reads into business events such as goods receipts, transfers and dispatch confirmations, which are posted to SAP through standard interfaces.
Is RFID better than barcode for inventory?
RFID is faster for bulk counts and reads at fixed points without handling each item. Barcode is cheaper per item and fine where volumes are modest and someone scans anyway. Many plants use both.
What read accuracy should we expect?
Accuracy depends on tags, placement, environment and read point design, so it has to be proven in a pilot. A good design also includes a rule for items that are not read, so exceptions are caught.
Related reading
References
Start with one line and one number
We scope one line, agree the number that should move, and show it moving before anything is scaled. You keep the code and the data.
Step 1
An engineer reads it
Not a sales bot. Our team replies within 24 hours with questions or times for a call.
Step 2
30 minute call
Your process, machines, systems and the number you want to move. We tell you honestly if we are a fit.
Step 3
A written scope for one line
What we would connect, what you would see, how long it takes. You decide; nothing starts without your approval.
Reviewed by Amey Kadle, Founder, Ajinkya Technologies. Last reviewed: .