Globally, billion of devices in heterogeneous networks are interconnected by the Internet of Things (IoT). IoT applications require a centralized decision-making system due to the failure-prone connectivity and high latency of such a system. Low-latency communications are a primary characteristic of applications. Since IoT applications usually have small payload sizes, reducing communication overhead is crucial to improving energy efficiency. Researchers have proposed several methods to resolve the load balancing issue of IoT networks and reduce communication overhead. Although these techniques are not effective, in terms of high communication costs, end-to-end delay, packet loss ratio, throughput, and node lifetimes negatively impact network performance. In this paper, we propose a communication overhead aware optimal cluster-based (COOC) routing algorithm for IoT networks based on a hybrid heuristic technique. Using three benchmark algorithms, we form load-balanced clusters using k-means clustering, fuzzy logic, and genetic algorithm. In the next step, compute the rank of each node in a cluster using multiple design constraints, which are optimized by using the improved COOT bird optimum search algorithm (I-COOT). After that, we choose the cluster head (CH) according to the rank condition, thereby reducing the communication overhead in IoT networks. Additionally, we design chaotic golden search optimization algorithm (CGSO) for choosing the optimal best path between IoT nodes among multiple paths to ensure optimal data transfer from CHs. To conclude, we validate our proposed COOC routing algorithm against the different simulation scenarios and compare the results with existing state-of-the-art routing algorithms.