FreshPod Connected Helmet Sanitization Platform

FreshPod India had early-stage machines deployed in the field, but the original software stack suffered from reliability bottlenecks: the machine controller lacked dynamic payment capabilities, operators had no visibility into machine health or revenue, and firmware updates required manual on-site visits. SolveMpire was engaged to engineer the complete software, firmware, and cloud modernization. We rebuilt the ESP32 firmware with deterministic state control, redesigned the DGUS display tools to handle dynamic Razorpay QR codes, and built a centralized cloud management platform with live heartbeats, transaction analytics, and remote OTA deployment. Today, the platform connects over 190 machines across India, processing thousands of daily sanitization sessions seamlessly.

Our team developed the ESP32 machine control architecture managing the multi-stage sanitization sequence (UV sterilization, fogging, thermal drying, and exhaust), door safety interlocks, DWIN touchscreen communication over UART, audio guidance via DFPlayer Mini, buzzer status feedback, Wi-Fi connectivity, time sync, and heartbeat telemetry.

We evolved the original static-QR workflow into a dynamic payment session architecture. Each transaction is dynamically generated by the cloud backend, rendered on the machine's display, and continuously verified. Once payment is confirmed, the system immediately authorizes access and triggers the sanitization sequence. We also implemented payment-session prefetching, preparing the next transaction's QR code while the current cycle finishes, cutting customer wait time between uses.

We developed a centralized management dashboard built on Next.js, Node.js, TypeScript, MongoDB, and Firebase. The platform provides: • Machine online/offline heartbeat monitoring & error logging • Transaction tracking, tap volume, and dynamic pricing management • Dealership, buyer, and operator role-based access control (RBAC) • Centralized OTA firmware versioning and deployment tracking • Machine-level activity analytics and operational telemetry

The platform evolved through two major architectural generations: • Generation 1 (Static Payment Architecture): Deployed across 150+ machines with static QR/payment workflow, MQTT transaction confirmation, and Firebase telemetry. • Generation 2 (Dynamic Payment & Cloud Architecture): Deployed across 40+ machines with dynamic payment sessions, backend verification, enhanced fleet monitoring, and OTA firmware management.

The platform includes a 3-year software and firmware update framework covering firmware updates, module upgrades, OTA deployments, payment improvements, and dashboard enhancements — enabling FreshPod to continuously upgrade its fleet remotely without on-site servicing.