Track & Trace System for LPG Cylinders

Who We Are

38 years of engineering LPG systems

Raghavendra Automation Pvt. Ltd. (RAPL) is a leading engineering solutions provider with over 38 years of specialized experience in the LPG sector.

As an ISO 9001:2015 certified company, RAPL has built a strong reputation for delivering high-quality turnkey solutions tailored to India's foremost LPG bottling operations.

Who We Help

Trusted across India's LPG industry

Major Oil Marketing Companies (OMCs) — Indian Oil Corporation (IOCL), Bharat Petroleum (BPCL), Hindustan Petroleum (HPCL) — and LPG bottling plant operators nationwide.

First implementation completed at IOCL.

System Overview

What our system can do

1

Zero human error in cylinder identification

2

360° high-speed QR code scanning

3

Real-time data communication to central servers

4

Plug-and-play integration with existing setups

5

Compliance with Gas Cylinder Rules (GCR 2025)

How It Works

From stayplate to server, in four steps

1

Each LPG cylinder receives a durable QR tag affixed to its designated inner stayplate.

2

Flameproof QR readers at designated Touch Points capture data at each operational stage.

Captured data on the monitoring software

3

Captured data is transmitted in real-time to a centralized server.

4

The system ensures safe, efficient operations compliant with Zone 1 hazardous area standards.

Key System Components

QR Code Tagging Unit

Durable stainless-steel tags, applied using a clinching mechanism.

TouchPoint QR Readers

Flameproof enclosures with 360° scanning via industrial-grade cameras.

Illumination System

PESO-approved LED lighting for clear imaging in every read.

Server Communication Module

Real-time data sync with local buffering capabilities.

AI OCR Module — Existing Data Mapping

Our advanced AI-powered OCR module accurately reads engraved, punched, or stenciled data already present on LPG cylinder stayplates.

Curved surface text recognition
Handling punched, engraved, or embossed data
Logic-based validation
AI retraining support for unique fonts

The Route

How one cylinder moves through the system

Redrawn from RAPL's process schematic — every scan, outbound and inbound, feeds the same cloud-based record.

Bottling plant → customer

Customer → bottling plant

At BP

QR code fixingStainless-steel tag fixed on the cylinder — stainless steel only.

Pass to carouselInfo passed to carousel for filling of empty cylinder.

Truck loading at BPQR scanned while truck is loaded at the bottling plant.

NOQR re-tagging — Step 1

YESContinue to carousel — Step 2

Inspection at plantIs the QR code present and fault-free?

Receipt confirmation at BPScanned to confirm the cylinder has arrived back at the bottling plant.

At Distributor

Unloading at distributorScanned while unloading at the distributor end.

Dispatch to customerScanned while dispatching to the customer.

Distributor → BP loading (empty)Empty cylinder scanned at the distributor, loading for BP.

Distributor unloading (empty)Empty cylinder scanned at the distributor, unloading.

At Customer

Delivery scanScanned at the customer end during delivery.

Customer pickup scanScanned at the customer end during empty pickup.

Now at: QR code fixing Status: Outbound

Statutory Testing Update

Provision to update the cylinder's record after statutory testing — new testing date, updated testing due date, modification in tare weight, and other key fields.

Cloud-Based SW Solution

Every scanning instance, in both directions, communicates with the cloud-based software solution — which in turn syncs with SAP / SDMA-CRM.

Post-Implementation

What the data tells you, once it's live

1 Real-Time Cylinder Location Know exactly where any cylinder is — at the plant, in transit, with a distributor, or with a customer.

2 Full Lifecycle History Every scan, every touchpoint, timestamped — a complete audit trail ready for a PESO inspection on demand.

3 Cycle-Time Analysis See how long a full round trip takes, and where time is actually being spent — plant, distributor, or customer.

4 Due for Statutory Testing Know which cylinders are due for statutory testing, and exactly when — so retesting is scheduled before it lapses.

5 Distributor & Route Performance Compare turnaround across distributors and routes to see where the fleet moves efficiently, and where it doesn't.

6 Duplicate Cylinder Detection Flags cylinders whose QR identity shows up more than once in the system — a sign of cloned tags or unauthorized refilling.

7 Tare Weight Integrity Each cylinder's verified tare weight is locked to its digital ID at registration, so physical tampering is easy to catch.

Operational & Regulatory Benefits

What changes, operationally

01
Full TraceabilityComplete tracking from cylinder entry to dispatch.
02
Regulatory ReadinessCompliance with Gas Cylinder Rules 2025 and the latest PESO guidelines.
03
Enhanced SafetyZone 1 hazardous area certification for all electrical components.
04
Improved EfficiencyAutomated scanning reduces turnaround times and enhances productivity.
05
Analytics & ControlException reporting, cycle-time analysis, and fault alerts.
06
Integration ReadyEasy integration into existing ERP or PLC systems.