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Suhana Spices: Digital batch intelligence and traceability

Altizon’s Digital Factory Platform helped Suhana Spices transform manual and siloed batch tracking into a connected, real-time system for productivity, quality, and sustainability across all plants.

Altizon’s impact

15-18%

productivity increase

25%

manpower productivity gain

5%

Sustainability gains through energy and water efficiency

The challenge: Manual data silos in complex spice manufacturing

Reliance on paper-based tracking created significant operational latency, preventing Suhana from establishing a unified, real-time view of line and batch-level performance across its manufacturing footprint.

Retrospective batch tracking
Paper-based batch tracking: Reliance on paper logs for silo-to- packer mapping created significant data gaps and prevented real-time process visibility.
Delayed ERP synchronization: Batch weights were recorded manually and uploaded to ERP only post-shift, resulting in persistent inaccuracies and latency.
Production reconciliation lags: MManual data entry forced a reliance on retrospective balancing, delaying the identification of material variances and financial discrepancies.
No operational visibility
Traceability gaps: The absence of a digital link between mixers, silos, and packaging lines prevented real-time tracking of material flow and batch lineage.
Resource blind spots: Manual tracking of energy and water consumption obscured efficiency leaks and prevented the calculation of per-batch resource intensity.
Inconsistent data baseline: Non-uniform reporting formats across plant locations blocked the cross-site benchmarking.
The scaling challenge
Systemic operational latency: Reliance on manual workflows created data gaps and production blind spots that compounded as the plant network expanded.
Diluted quality standards: The lack of a centralized digital layer made it increasingly difficult to enforce uniform efficiency and quality protocols across new sites.
Fragmented data architecture: The absence of a connected ecosystem between the plant floor and ERP prevented the real-time data flow required for enterprise-scale optimization.

Suhana required a unified digital layer to connect production lines, automate ERP integration, and provide real-time visibility into productivity and resource usage.

The solution: Altizon’s digital factory across the enterprise

Altizon deployed its Digital Factory Platform (DFX) across Suhana’s plants — standardizing data collection, enabling real-time analytics, and connecting machines, utilities, and ERP into a single system of record.

Production performance
  • Live data captured directly from mixers, silos, and packing lines.
  • Continuous tracking of production output, downtime, and quality losses.
  • Real-time dashboards showing availability, performance, and quality losses—helping teams act before bottlenecks build up.
  • Shift and line summaries give supervisors visibility into throughput, changeovers, and manpower usage.
Outcome:
  • Operators and supervisors see live performance and top losses.
  • Management gets instant visibility into trends across plants.
  • Faster actions and sustained productivity improvements.
  • Every batch is tracked digitally from raw material intake to finished consumer packs.
  • Batch movement is captured across mixers, silos, and packing lines without manual intervention.
  • Batch codes flow automatically from SAP to the plant floor, linking production data with material movement in real-time.
  • SCADA signals and barcode scans identify the exact batch path, eliminating manual logging and guesswork.
Outcome:
  • Complete batch-level visibility from production to packaging.
  • Instant traceability for audits and recalls.
  • Faster reconciliation and audit-ready compliance at all times.
  • Real-time energy and water data is captured directly from utilities and production equipment.
  • Dashboards provide live visibility into consumption patterns and loss points.
  • Efficiency ratios and recovery opportunities are tracked consistently across plants.
  • Continuous insights help teams identify waste and improve resource utilization.
Outcome:
  • Teams act on live data to reduce waste.
  • Improved energy and water efficiency across operations.
  • Stronger, data-backed sustainability performance.
  • A single dashboard brings together performance, traceability, and sustainability KPIs from all plants.
  • Leadership teams can compare lines and plants in real-time.
  • Trends and deviations are visible instantly, enabling quicker corrective actions.
  • Standardized reports ensure consistent performance definitions across locations.
Outcome:
  • Unified visibility across plants.
  • Faster, more consistent decision-making.
  • A shared performance language and stronger accountability.
  • Real-time feedback from the plant floor flows directly into ERP systems.
  • Batch weights and order data are posted automatically, without manual reconciliation.
  • Production status is visible to planners as it happens.
  • Planning and execution are tightly connected through live data synchronization.
Outcome:
  • ERP reflects the plant floor in real-time.
  • Faster, more accurate production planning and scheduling.
  • Reduced delays and more data-driven execution.

How Suhana experienced measurable and sustainable gains

Before Altizon
After Altizon
Outcomes
Productivity
Manual entry of output and downtime; delayed visibility
Automated data capture and real-time OEE dashboards
15–18% OEE improvement and faster loss analysis
Traceability
Batch path from mixer to packer tracked manually
Digital batch trace with SAP codes and SCADA integration
Instant traceability and audit-ready reports
ERP integration
Manual posting of batch data after shifts
Real-time synchronization between SAP and DFX
Zero delay in material and batch reconciliation
Manpower efficiency
Multiple manual logs and redundant reporting
Single digital interface for all plant operations
25% improvement in manpower productivity
Energy and water tracking
Fragmented, manual utility data
Unified dashboards across all plants
Real-time visibility into energy and water efficiency

“Digital transformation is not just about adopting technology—it's about enabling smarter, more agile decision-making. With Altizon’s Digital Factory platform, we’ve taken a strong step in that direction.”

— Anand Chordia, Director – Technology & Innovations, Suhana

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