Customer Case Study · Cold Chain · FMCG · FSSAI Compliance
Leading FMCG Manufacturer — South India
How KLVIN's THRIVE.v2 sensors and SENTINEL platform delivered continuous, FSSAI Schedule 4 compliant environmental intelligence across a large-scale food manufacturing facility — turning a 3-month pilot into an expanding multi-vertical partnership.
THRIVE.v2 Devices Deployed
Temperature Precision
Product Loss Events
Post-Pilot Scale-up
The Challenge
Large food manufacturing facilities share a common set of environmental monitoring challenges with direct implications for FSSAI compliance, product quality, and operational cost.
Gaps in Continuous Temperature Visibility
Without automated, round-the-clock monitoring, temperature excursions in cold storage zones can go undetected between manual checks — creating windows of microbial risk.
Humidity Drift Goes Undetected
Progressive humidity build-up is invisible until damage occurs. Hygroscopic food products are especially vulnerable without automated trend detection.
FSSAI Audit Trail Compliance
FSSAI Schedule 4 mandates continuous, retrievable environmental logs. Manual record-keeping struggles to meet this reliably across multiple zones.
Light Exposure Monitoring
Light intensity is frequently overlooked in food storage. UV and visible light accelerate lipid oxidation and degrade natural colourants and vitamins.
The KLVIN Solution
KLVIN deployed three THRIVE.v2 environmental monitoring nodes across the client's cold storage zones as part of a focused 3-month pilot beginning August 2025. Each device captured three critical environmental parameters at continuous intervals, feeding live data into the SENTINEL cloud platform and the KAIROS AI analytics engine.
Ambient Temperature (aT) — Continuous monitoring at ±0.3°C precision with instant alerts when readings approach defined thresholds.
Relative Humidity (aH) — Real-time humidity tracking with KAIROS AI trend detection — flagging progressive humidity build-up before compliance thresholds.
Light Intensity (LDR) — Photoresistor-based light monitoring capturing both sustained exposure levels and door-open spike events.
SENTINEL Platform — All sensor streams feed into a cloud dashboard with real-time alerts, historical trending, and export-ready FSSAI audit logs.
KAIROS AI Reports — AI-generated operational reports analysing environmental patterns, detecting trends, and surfacing risks automatically.
Pilot Results
Over the monitoring window, the KLVIN system surfaced a detailed environmental intelligence picture — establishing a baseline, validating strong temperature management, and detecting a humidity trend early enough to act on.
30°C ±1.5°C maintained throughout. Zero critical thermal excursions.
Zero product loss events during the monitored pilot period.
Controlled light levels with door-open spikes identified and explained.
KAIROS AI surfaced a rising humidity trend before a critical threshold.
Pilot completed on schedule. Contract extended within weeks.
Client doubled THRIVE.v2 deployment across additional storage zones.
KAIROS AI — Early Warning in Action: The KAIROS engine detected a statistically significant upward humidity trend across the monitoring window and surfaced the finding in the AI report — giving the facility team actionable lead time to investigate and intervene before the trend reached a critical threshold.
FSSAI Compliance Enablement
Continuous Temperature Logging
THRIVE.v2 sensors record temperature at continuous intervals — delivering the uninterrupted cold storage log FSSAI Schedule 4 requires.
Digital Audit Trail
SENTINEL stores all environmental data in timestamped, retrievable logs — export-ready for FSSAI inspections without manual preparation.
Automated Threshold Alerts
KAIROS threshold alerts trigger via SMS, email, and dashboard — providing automated breach notification across the facility team.
Light Environment Monitoring
LDR monitoring provides documented evidence of light control for light-sensitive food products — rarely captured before IoT deployment.
What Happened After the Pilot
The client did not simply renew — they expanded. A 3-month cold storage pilot evolved into a multi-vertical industrial intelligence partnership.
Pilot Launch
3 THRIVE.v2 devices deployed across cold storage zones. SENTINEL platform activated. KAIROS AI reporting commenced.
Pilot Validated — Contract Extended
Pilot objectives met. Client extended the cold storage monitoring engagement by 6 months, retaining all 3 THRIVE.v2 devices.
2× Device Scale-up
Client doubled the number of THRIVE.v2 devices, expanding coverage to additional storage zones.
New Vertical: Asset Monitoring
KLVIN initiated a new engagement for critical process asset monitoring at the same facility — expanding scope beyond cold chain into plant operations.
The outcome: The client's decision to double device count and add a new monitoring vertical is the clearest possible validation of the platform's real-world value.
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