Pack-Size-Wise Stock Verification for a Chemical Manufacturer with Inveck
Every Kilogram, Every Pack, Accounted For
A specialty chemical manufacturer in India moved from counting total kilograms to verifying stock pack by pack — recording, for example, 20 packets of 10 kg and 40 packets of 20 kg — and can now trace each breakup back after the count.
These numbers don’t happen by chance. See how it was done
Who is the client?
The client manufactures specialty chemicals in India, supplying the pharmaceutical, agrochemical and coatings industries. Its stores hold powders, granules and liquids in many pack formats — 5 kg, 10 kg, 20 kg and 25 kg bags, drums, carboys and bulk containers — often for the same material code.
The ERP holds stock in kilograms or litres per item. Physical stock, however, sits on the floor as packs. For the business, a correct total is not enough: production, dispatch and finance all need to know how that total is packed.
Book a DemoChallenges that held them back
Auditors counted packs on the floor, multiplied them out on paper, and reported only the total kilograms. The breakup that produced the total was lost.
Totals with no breakup
A count of 1,000 kg said nothing about whether it was 100 bags of 10 kg or 50 bags of 20 kg. Planning and dispatch had to recheck the floor.
Arithmetic errors on the floor
Multiplying packs by pack weight by hand, across several pack sizes, created mistakes that showed up as false variances.
Mixed pack sizes in one location
The same material sat in 10 kg and 20 kg bags side by side. Packs were missed or counted under the wrong size.
Variances that could not be explained
When the physical total did not match the ERP, there was no record of how it was built, so reviewers could not tell whether a pack size was missed or miscounted.
No trace after the count
Weeks later, finance and auditors asking "how was this figure arrived at?" had only a handwritten sheet, if it could be found.
Loose and part-filled packs
Opened bags and part drums were noted inconsistently or left out altogether.
How Inveck solved it
Inveck's configurable capture fields were set up so that every count is entered as a packaging breakup, not just a total. For each item, the auditor records the pack size and the number of packs, as a separate entry for each pack size found. Together, the entries make up the item's counted quantity, and each one stays on record.
Book stock for each store was uploaded as a milestone, with custom fields for Pack Size and No. of Packs added to the count screen. Pack formats used by the client were agreed up front so every auditor recorded them the same way. Auditors download the milestone to their phones and count offline in the stores, syncing once back online. Training centred on one habit: one entry per pack size.
Pack-size capture fields
Each entry records pack size and number of packs alongside quantity, location and remarks.
One entry per pack size
10 kg and 20 kg bags of the same item are entered separately, so no size is merged or missed.
Entry history per item
Every entry is listed against the item with its quantity, location, user and timestamp.
Remarks for loose packs
Opened bags, part-filled drums and damaged packs are recorded with a remark instead of being skipped.
Multi-location counts
The same material in several bins is captured per location and rolls up to one item.
Offline counting
Milestone data stays on the device for stores and godowns with poor network.
Live progress and pending review
Completion %, updated vs pending lines and a Review Pending list ensure no item is skipped.
Excess / Shortage review
Variances against book stock are shown per item, with the breakup available to explain them.
Digital Incharge sign-off
The store Incharge signs on the device to close the count.
How the Breakup Is Captured
Auditors enter what they see on the floor, one entry per pack size, and the breakup stays attached to the item's count.
Pack-size breakup for one item · 2 entries
The same pattern covers drums, carboys and loose packs; a part-filled pack is entered with its actual quantity and a remark.
The results
The client now knows not just how much stock it holds, but exactly how it is packed — and can prove it long after count day.
A breakup for every item
Every counted quantity is backed by its pack-size entries, such as 20 × 10 kg and 40 × 20 kg.
No more floor arithmetic
Auditors record what they see — pack size and pack count — instead of working out totals on paper.
Variances explained, not argued
When a total differs from the ERP, reviewers open the breakup and see which pack size is short or excess, then recount just that.
Full traceability after the count
Finance, planning and auditors can look up any item and see each pack-size entry, where it was found, who recorded it and when.
Better planning and dispatch
Knowing the pack mix on hand lets teams plan issues to production and customer orders without rechecking the floor.
Loose packs captured
Part-filled and opened packs are recorded with remarks, so they are counted rather than written off.
Verification time down 40%
Faster counting and same-day variance review shortened the full verification cycle.
Earlier our count sheets gave us a total in kilograms and nothing more. With Inveck, our team records exactly what is on the floor — so many bags of 10 kg, so many of 20 kg — and that breakup stays with the count. When finance or our auditors ask how a figure was arrived at, we can show them in a minute.
More case studies
Stop Counting Totals. Start Counting What's Really There.
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Or WhatsApp us at +91 75229 88834On the walkthrough you’ll see
- The full count flow on mobile
- Live variance dashboard & reports
- How it fits your ERP or Excel
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