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Tata Innoverse-Problem Statements-April to May 2021

Reward: 3 Lakh INR to 10 Lakh INR

About Tata Innoverse:

Tata innoverse is an open innovation platform by Tata industries to solve challenges for various problems stated by the organizers. By this initiative the industry is targeting to solve many real world problems by reaching out to skilled solvers internationally and also to provide them a best platform to demonstrate their ideas, skills and creativity to develop unique and best solutions to solve real world industry challenges. The best problem solvers get rewarded, and also they become trusted technology partner with Tata industries.

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Problem Statement (Apr-May 2021):

Galvanization is the process of applying a protective zinc coating to steel, to prevent rusting. The most common method of galvanization is hot-dip galvanizing, in which the wires are submerged in a bath of molten hot zinc. They have a continuous hot-dip galvanization setup for producing galvanized (GI) wires, which also imparts a glossy appearance to them. ‘Extent of gloss or shiny appearance’ is one of the parameters used to make a perceptible difference in the quality of GI wires.

They want a solution that will help quantify the ‘glossy/shiny appearance’ of the wire bundle so as to compare it with another bundle, which may or may not be lying next to it. The solution may quantify (or at least rank) the ‘glossy/shiny appearance’ of various bundles, which may be lying in different light/ambient conditions. Wire size in the bundle may vary from 0.9 mm to 6 mm. The dimension of a typical bundle (diameter X Height) is ~3 ft. * 4 ft. They are not looking for a solution to determine the ‘glossy/shiny appearance’ of a specific point on the wire.

2.Measurement of coating thickness of Galvanized Iron (GI) wires

Galvanization or galvanizing is the process of applying a protective coating to steel or iron, to prevent rusting. The most common method of galvanization is hot-dip galvanizing, in which the parts are submerged in a bath of molten hot zinc. We have a continuous hot-dip galvanization setup for producing galvanized iron (GI) wires. The wire diameters range from 1.4 - 5 mm and corresponding zinc coating range from 50 - 300 gsm i.e. 7 to 50 microns.

It is sometimes observed that there is a variation of zinc coating across the length of wire. Currently, we undertake offline zinc coating tests (volumetric zinc coating as per IS 6745) from test samples. This is a reactive mode of determining the coating thickness and does not give continuous feedback to the operators. Any necessary corrective action is thus delayed.

Hence, they are looking for a portable zinc coating measurement system which will quickly provide the coating thickness (online or portable offline) and help the operator to correct the process parameters, without having to cut the test samples & wait for results.

3.Automatic Chemical Weighing And Feeding

Leather hides are imparted different colours based on customer requirements. This colour has a standard formula of making, with definite proportion of various chemicals mixed in sequence. These chemicals are in liquid form, having different viscosities. The chemicals are mixed together in a rotating drum to form a colour which is then sprayed on the leather hides using a spray gun. Each leather hide requires 5- 6 layers of different chemical mixes coated using spray gun at different intervals, each coat having different formula and proportion. Currently in this process, the operator collects the chemicals from the store room, weighs and feeds them into the rotating drum as per the recipe, defined in the SAP system.

This whole task of collecting, weighing and feeding the chemicals to the rotating drum is done manually. Therefore, it is quite inefficient and prone to errors. The operator may either miss out a chemical or use incorrect quantities of the chemical or may not follow a specific order. All this can lead to incorrect colour being imparted to the leather, which will not be known until the first batch of leather hide is coloured. Therefore, they need an automated process of colour making.

4.Avoiding iron-ore to freeze in bins in sub-zero temperatures

Tata Industries mine and process high-grade iron ore from our hematite deposits in the Menihek region of Labrador and northern Quebec, Canada. Fines and superfine material from our beneficiation plant are produced with minimum 64% Fe while our DSO (Direct Shipping Ore) facilities crush, screen and dry 60%-62% Fe iron ore for direct shipping.

The ambient temperature reaches -10 to -40 Deg C in winter and the low temperatures cause problems such as iron ore freezing and choking, thereby reducing the productivity.

Proposal Questions:

  1. Title

  2. Please share your solution

  3. What other solutions have you seen in the market for this problem? What have been the flaws in those solutions?

  4. Please define the problem statement as understood by you

  5. What positive and unique results do we expect to see from your solution?

  6. What is the estimated investment required to implement your solution at our end?

  7. Co-Solvers Details

Who can Apply:

Tata InnoVerse is open for entities, individuals, teams, academicians, scientists, start-ups, companies, research centres and universities to submit their proposed solutions.


  • 3 Lakh INR to 10 Lakh INR

.............INNOVATE TO WIN..............


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