Challenge

The client had experienced multiple near-miss incidents involving overheated machinery and friction-induced sparks. Traditional fire detection systems (smoke detectors and manual inspections) were reactive and often too slow to prevent escalation. A single fire event could result in millions of dollars in equipment damage, production loss, and insurance claims.

Solution: Thermal Imaging CCTV System

To proactively address fire risks, the client implemented a thermal imaging CCTV system integrated with their existing automation and safety infrastructure. The system was designed to:

• Continuously monitor heat signatures across critical zones.

• Detect abnormal temperature rises before ignition.

• Automatically shut down machinery and activate fire suppression systems.

Deployment Strategy

• Coverage Zones: Cameras were installed in high-risk areas including:

  • Hydraulic press stations

  • Conveyor belt motors

  • Material storage zones

  • Ventilation and exhaust systems

• Smart Thresholds: Each camera was configured with temperature thresholds based on machinery specs and ambient conditions.

• Automation Integration: The system was linked to the factory’s control network to trigger:

  • Immediate machine shutdown

  • Alert notifications to safety personnel

  • Activation of localized fire suppression systems

Incident Prevention Example

In July 2025, a conveyor motor began overheating due to a lubrication failure. The thermal camera detected a temperature spike of 45°C above normal. Within 5 seconds, the system:

1. Sent an alert to the control room.

2. Shut down the conveyor line.

3. Activated a mist-based suppression system.

4. Prevented ignition and halted potential fire spread.

Results

• Zero fire incidents since system deployment.

• Millions of dollars saved in potential fire damage, downtime, and insurance costs.

• 20% reduction in unplanned maintenance due to early heat anomaly detection.

• Improved compliance with workplace safety regulations.