Achieving Global Traceability with RFID-Enabled Product Serialization

Client Overview

The Challenge

Thokoman Foods is a manufacturer of premium peanut butter products distributed across multiple regions, including South Africa and Saudi Arabia. The company needed a comprehensive RFID-based traceability system to monitor every batch of its “Goody” peanut butter products — from production to export.

The challenges included:

• Inability to track products at the case or pallet level across multiple warehouses.
• Manual data entry during dispatch, causing errors and delays.
• Lack of real-time visibility for stock movement between South Africa and Saudi Arabia.
• Difficulty in reconciling received shipments with dispatch manifests.

The goal was to design a fully automated serialization and tracking solution that could ensure 100% product traceability, minimize losses, and enhance warehouse operations across international locations.

The DreamzCMMS Solution

DreamzCMMS implemented an RFID-enabled production-to-distribution tracking system for Thokoman Foods.
The solution was first rolled out as a Proof of Concept (PoC) for the “Goody” SKU line to test end-to-end serialization, tracking, and real-time reconciliation between production, local warehouse, and international distribution centers

Key features of the implementation:

1. Bulk Serialization

• Each case (tag) is serialized using RFID handheld readers immediately after production.
• Assets are automatically created in DreamzCMMS, with each tag linked to a unique product and quantity unit.
• Product shelf life is calculated dynamically based on production and expiry dates.

2. Production to Warehouse Movement

• Handheld RFID readers are used to move serialized items from the production floor to warehouses.
• Every movement is automatically logged in DreamzCMMS to maintain a complete history of tag movement.
• The system generates alerts for missing, duplicate, or unscanned tags, ensuring data consistency.

3. Dispatch from South Africa to Saudi Arabia

• Fixed RFID readers are installed at dispatch bays to track outbound shipments automatically.
• A dispatch reference manifest is generated for each shipment, listing all scanned tags.
• Real-time data synchronization ensures that Saudi Arabia warehouses can view shipments before arrival.
• Exception handling features automatically flag any discrepancies in case count during loading.

4. Receiving at Saudi Arabia Warehouse

• Fixed RFID readers detect all arriving shipments.
• DreamzCMMS performs automated reconciliation against the dispatch manifest, instantly identifying missing or extra tags.
• Instant inventory updates reflect in the system once reconciliation is completed.

Key Features Utilized

• Bulk Serialization with RFID Encoding
• Handheld and Fixed RFID Reader Integration
• Automated Dispatch & Receiving Reconciliation
• Real-Time Cloud Synchronization between Sites
• Dynamic Expiry and Shelf Life Calculation
• Alerts for Missing or Duplicate Tags
• DreamzCMMS Web Dashboard for Analytics and Audit Trail

Key Results / Outcomes

• 100% traceability of every serialized “Goody” SKU case between South Africa and Saudi Arabia
• Eliminated manual reconciliation between dispatch and receiving teams
• Real-time visibility into global stock movement via DreamzCMMS dashboards
• Improved shipment accuracy and reduced loss through automated RFID validation
• Accelerated dispatch process, saving several man-hours per shipment
• Enhanced data accuracy and auditability for production and logistics teams

Technology Stack

• DreamzCMMS Cloud Platform
• Chainway RFID Hardware:
  • UR4A Fixed RFID Reader
  • Ant-RC12 12dBi Panel Antenna
  • C72 UHF RFID Handheld Reader
• Fixed & Mobile RFID Gateways for production and dispatch points
• Dreamz RFID RFID App for Serialization and Move Tracking
• Cloud Synchronization Module for South Africa ↔ Saudi Arabia data sharing
• Real-time Reporting Dashboard

Support document (Optional)