Everything on rails, automated. India's first AI-native, end-to-end rake management platform — Eight stages and two extensions, from FOIS alert to reconciled unloading, with demurrage falling 15–25% and not a phone call in the chain.
10 modulesAt ₹150 per wagon per hour, demurrage is the meter that never stops. Yet most plants still run rail logistics on phone calls to the railway control room, manual FNR checks, and reconciliation done days later in a spreadsheet. Rake Guard replaces the entire chain with one AI-powered application: it sees the rake coming before your team does, verifies every wagon, sequences the tippler, weighs each wagon in motion, and reconciles the lot against FOIS — automatically.
Live Rake Position pulled directly from Indian Railways' FOIS. FNR auto-verified against consignment data, with mismatches flagged before the rake reaches your siding. Advance arrival alerts give yard crews hours — not minutes — to stage lines, equipment, and manpower.
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AI tracks yard occupancy and routes wagons by track availability, priority, and constraints automatically, with supervisor alerts on any reroute. Results across deployments: 10–25% rake TAT reduction with zero new infrastructure.
A bulged or deformed wagon does not announce itself. It moves through the yard like any other and is discovered at the tippler, usually jammed inside one, with the line stopped behind it and hours of recovery ahead. Rake Guard flags these wagons on approach and diverts them before they get there. Wagon condition becomes data, not a surprise.
The platform reads incoming rake composition, tippler availability, material type, and hopper status in real time and assigns every wagon its optimal path. Camera-based alignment checks, automatic blockage detection, and instant rerouting on downtime keep unloading continuous.
Position, tip, reset — governed by AI logic rather than operator judgment. After each tip, cameras inspect the wagon bed and fire a re-tipple automatically if material remains. Zero-human-presence verification runs before every cycle: the safety interlock cannot be bypassed because it isn't a switch; it's vision.
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Gross weight captured per wagon, tare routed automatically, net computed and validated against ULIP-FOIS — with digital slips and automated mismatch alerts. Reconciliation stops being a month-end argument and becomes a live data feed.
Incoming Rakes detected in advance; boom barriers actuated without manual intervention; AI obstacle scanning while the track is live; automatic reset and logging after passage. The most accident-prone point on the plant rail infrastructure, made boring.
Hot metal moves on rails too. Ladle Tracking extends Rake Guard from the siding into the plant's internal rail network: 360° real-time monitoring of ladle and transfer-car movement between furnace, melt shop, and casters, with SOP-compliance checks, idle and delay alerts, and predictive insights that cut thermal losses, safety risk, and unplanned downtime. The same rail-side AI that watches your rakes watches your most dangerous cargo.
Read moreSame spine, same login, Switch these on when the core chain is running.
Hear what our clients say about our AI solutions and their impact on their business.
The mining management system improved our operational efficiency and provided valuable insights. A great experience working with them.
Gurpreet Sabharwal
MD, Tirupati Group
At Welspun, we needed complete operational control across weighbridges and loading yards — not just automation. Helious delivered exactly that. Zero Manpower 30 sec operations at weighbridges, automated loading intimations, real-time anomaly escalation, and a VAPT-certified dashboard connecting every touchpoint. Every scenario we could think of was already accounted for. AI adoption in heavy industry requires that level of trust, and Helious has built it.
Karthikeyan M
Resident Director, Welspun World
Gallantt’s first AI-powered weighbridge at Gorakhpur is now live, fully integrated with SAP S/4HANA for seamless data integrity. With AI material identification, ANPR, and human detection, it has improved plant TAT and reduced congestion — a major Industry 5.0 milestone delivered with Helious Tech Solutions.
Jagroop Singh
President & CIO, Gallantt Group
The AI-Unmanned Weighbridge System from Helious Tech Solutions has improved our weighing operations with greater accuracy, faster processing, and reduced manual effort. The team’s support and seamless execution made the entire experience highly effective.
Dinesh Gupta
AVP, Godawari Power and Ispat Limited
Rake Guard is India's first AI-driven rake intelligence system designed for steel plants, power plants, and cement industries. It automates the entire workflow — from FOIS tracking integration and FNR verification to wagon tippler automation — eliminating manual processes and delivering real-time rail logistics visibility.
Rake Guard pulls live rake positions directly from Indian Railways' FOIS tracking integration. It auto-verifies freight data, sends advance arrival alerts, and flags mismatches before the rake reaches your siding — enabling proactive rail wagon monitoring with zero dependency on manual railway control room calls.
A wagon tippler physically rotates the wagon to unload material, ideal for bottom-sealed wagons, while a track hopper relies on gravity discharge through wagon doors. Rake Guard's AI rail logistics platform supports wagon tippler automation with safety interlocks, making it the preferred choice for high-throughput steel and power plants in India.
Yes. Rake Guard significantly reduces coal rake turnaround time by automating wagon identification, sequencing tippler operations, and providing real-time tracking from origin to plant. Faster unloading cycles, predictive arrival alerts, and automated weighing collectively cut idle time and improve overall plant throughput.
Absolutely. Rake Guard is purpose-built for AI rail logistics in steel plants, mining, cement, and thermal power industries. It offers bulged wagon detection, AI-based human detection in restricted zones, and complete wagon-wise traceability — making it a comprehensive rake management system for India's heavy industry sector.
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Share-ready ROI report
Rake Guard ROI Report
Value assessment opening spread
Executive summary
Projected annual savings
₹2.4 Cr+
per year
Current TAT
12.5 hrs
Expected TAT
8.5 hrs
TAT Reduction
32%
Financial outcome
Annual value and investment return
Top metrics
Net Annual Value
₹1.9 Cr
Payback Period
7 Mos
Deploy AI-powered automation and real-time intelligence to make your industrial processes faster, smarter, and more efficient.
99.95%
Uptime
24/7
Support
26+
Happy Customers
