Built a fault-tolerant IoT data pipeline processing 100K+ devices with custom protocol integration and live dashboards
A global supply chain solution company needed to monitor temperature-sensitive shipments across 100K+ IoT devices using proprietary communication protocols.
The existing system struggled with data loss during transmission, lacked real-time monitoring, and had no automated alerting for processing delays or temperature excursions. With pharmaceuticals, food, and perishable goods worth millions in transit, data reliability was critical.
Temperature-sensitive supply chain
Real-time tracking of temperature excursions for pharmaceuticals, food, and perishables
GPS and geofencing for shipment location and route optimization
Battery status, signal strength, and connectivity monitoring
Automated reports for FDA, USDA, and other regulatory requirements
Any data loss or processing delay could mean spoiled goods worth millions
Built a scalable, resilient system for processing high-volume device data with custom protocol integration
Implemented proprietary IoT device communication protocol with secure authentication, message queuing, and retry mechanisms for reliable data transmission.
Built on SQS with multiple redundancy layers, automatic failover, and data validation at each stage to ensure zero data loss even during network interruptions.
Optimized data processing to handle 100K+ concurrent device streams with sub-5 second end-to-end latency using distributed processing and intelligent batching.
Implemented automated alerting for temperature excursions, device connectivity issues, processing delays, and data anomalies with configurable thresholds.
Built interactive dashboard showing real-time device status, temperature trends, location maps, and processing metrics with drill-down capabilities.
Automated generation of compliance reports for regulatory requirements including temperature logs, chain of custody, and audit trails.
Device registry, secure communication, and message broker
Reliable message queuing for fault-tolerant data processing
Time-series database for IoT telemetry data
Real-time dashboards and visualization
Ingestion → dashboard latency reduced
Reduced end-to-end telemetry latency from ~30–60 seconds to ~8–15 seconds by optimizing the ingestion pipeline, queue processing, and database writes, so excursions (temperature/shock) showed up faster and teams could react sooner.
Zero data loss pipeline
Fault-tolerant architecture ensured no data loss during network interruptions or system failures, maintaining complete audit trails.
Concurrent device support
Successfully scaled to handle 100K+ concurrent IoT device connections with linear performance scaling for future growth.
Real-time temperature monitoring and immediate alerts reduced spoiled goods by catching temperature excursions early.
Automated regulatory reporting saved hundreds of manual hours and reduced compliance risks.
Live dashboard provided end-to-end supply chain visibility from manufacturer to end customer.
Device health monitoring enabled predictive maintenance, reducing unexpected device failures by 60%.
Data ingest to dashboard
24/7 operational reliability
Fault-tolerant architecture
Scalable processing capacity
Whether you're processing thousands of devices or building complex monitoring systems, we can help scale your IoT infrastructure.
Device protocols, data pipelines, connectivity
Stream processing, monitoring, dashboards
Fault tolerance, performance, reliability
All client information is kept confidential under NDA agreements
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