98% Reduction in Bucket Overflow Incidents at GHCL Chemical Plant

GHCL | Chemical Manufacturing | INDIA

Reduced Downtime Monthly Cost Savings Zero Manual Intervention Manpower Optimization

Problem Statement

THE CHALLENGE

The bucket feeds the Lime Kiln with material as per SOP-defined weight. However, when the kiln is not fed completely - especially during monsoon season or with high-moisture raw material - the carry-over material returns to the bucket, causing overfeed and occasional overflow.

Before automation, visual monitoring was entirely human-dependent, making it prone to error during 24/7 operations. Persistent overfilling led to equipment strain, material wastage, and recurring safety hazards across high-traffic manufacturing corridors.

Challenges

Frequent Overflow Incidents

2-3 incidents per month, increasing further during monsoon due to higher raw material moisture levels.
Production Downtime

~1.5 hours downtime per incident, resulting in over 10 hours of monthly disruption across 7 production lines.
Safety Risks on Floor

Material spillage in high-traffic plant areas created persistent fall hazards for floor staff.
Operational & Material Losses

Raw material wastage, cleanup efforts, and repeated equipment stress led to ongoing operational losses.

Solution

THE SOLUTION

By leveraging advanced computer vision, we developed a 7-camera monitoring system that integrates directly with the facility's existing OT hierarchy, requiring no separate monitoring platform and no disruption to live operations. Each camera is dedicated to precisely one Bucket, enabling per-line volume tracking with zero cross-line ambiguity.
Flow: Live camera feed → Material Crossing Marked Line → Alert → Auto trip Conveyor to stop Material

7 dedicated AI-enabled cameras deployed, one per conveyor line for precise volume tracking.
CCTV and OT systems unified into a single real-time operator dashboard.
Automated OT tripping triggered instantly on carry-over detection to prevent overflow escalation.
Floor-level alarm integration added for immediate operator alerts and backup response.

WHAT CHANGED AFTER