India's Industrial AI Pioneer

Computer Vision
and
IIoT Solutions

Ecoloop delivers Industrial IoT and Computer Vision solutions that make Industries, Mines and Utilities Smarter, Safer and Efficient — engineered in Bhilai, India.

30+

Years of Industrial Automation Experience

25+

Solutions deployed : Design - Deployment

16+

Industries Catered

3

Years of Innovation

Our Technology Domains

Two Pillars of Industrial Intelligence

Ecoloop builds purpose-built solutions across Industrial IoT and Computer Vision, tailored to the reality of industrial operations.

📡

Industrial IoT

Connect every PLC, sensor, and machine into a unified monitoring fabric. Real-time visibility, predictive maintenance, and energy intelligence across your entire plant.

e-LOTO++Energy MonitoringPLC/DCS RemoteEquipment HealthAsset Tracking

👁️

Computer Vision

Turn cameras into process control,intelligent safety guards and quality inspectors. Detect PPE violations, measure hot lengths, profile temperatures, and trigger PLC actions in real time.

Electrical PPE AdherenceCut-to-LengthThermal ProfilingHazardous Zone AI

Industries Served

Purpose-Built for Your Industry

Every solution is customised to the specific process, equipment, and safety requirements of each sector.

🏗️ Steel & Aluminium

Blast Furnace — Human Detection & CO Safety

SMS — Billet Cut-to-Length (Visual + Thermal)

Rolling Mill — Shear Head Cut, Hot Length

Arc Flash PPE Adherence at HT Systems

Ladle, Torpedo & Crane Health Monitoring

⛏️ Mining & RMHS

Coal Oversize Detection at Belt Speed

Conveyor Defect Detection

Pellet/Sinter Machine Health

360° Eye for Excavators & Wheel Loaders

Belt Switch Monitoring

⚡ Power & Utilities

Sub-Station Remote Monitoring

Energy Monitoring (Power, Air, Gas, Water)

DG & Compressor Controller

Pump House @ Cloud

Load Shedding & Tariff Optimisation

🏚️ Cement & Process

Stack Smoke Detection

Conveyor Health Monitoring

PLC Remote Monitoring

🏥 Medical IoT

Patient Remote Monitoring

Hospital Process Automation

Special Medical Gadgets

Trusted by Industry Leaders

Industrial IoT Platform

Remote Monitoring & Control at Your Fingertips

Our IIoT platform connects PLCs, sensors, and field devices into a single dashboard. Monitor temperature, pressure, flow, energy, and vibration from anywhere.

✓Real-time PLC/DCS parameter monitoring
✓Predictive maintenance via pattern analytics
✓Energy consumption pattern analysis
✓Remote troubleshooting — no site visit needed
✓IT-OT isolation hardware for cybersecurity

⚡ Live Dashboard

Energy Monitoring System

Real-time utility consumption tracker

87%

Efficiency

↓23%

Energy Cost

99.1%

Uptime

PPE Compliance

AI-powered · Real-time

Thermal Alert

Bearing over-temp detected

e-LOTO Active

3 locks · Secure

Computer Vision AI

Cameras That Work as Hard as Your Workers

One camera, multiple AI algorithms running simultaneously — detecting PPE violations, measuring lengths, profiling temperatures, and triggering PLC actions in real time.

✓Visual & Thermal camera solutions
✓11 Arc Flash Suit types trained & deployed
✓Closed-loop interfacing with DCS/PLC
✓Works in dusty, hot industrial environments
✓Email/SMS alerts + dashboard notifications

🎥 CV Safety Monitor

⚠️ Electrical PPE Violation — HT Room Camera 3 — 14:32

✅ Human Zone Clear — BF Cast House

✅ Coal Size under Control — Power plant feed

🌡️ Pellet Discharge Bed Temp — Normal Range

Made in INDIA

Proven in Steel, Mining & Power plants across India

Steel & Aluminium

SMS, Rolling Mills, Pellet, Smelting plants

Power & Utilities

Substations, DG sets, Compressors

SME

Packaged Food, Sugar, Poultry, Textile, Pharma

Medical IoT

Patient remote monitoring

Why Ecoloop

Your Innovation Partner

We don't just sell software — we solve real operational problems at the plant floor with technology that is affordable, scalable, and built for industries.

01

End-to-End Capability

From hardware integration and sensor deployment to software platforms and dashboards — we handle the complete solution lifecycle.

02

Industry-Specific Expertise

Deep domain knowledge in steel plants, mining, and heavy manufacturing makes our solutions production-ready from day one.

03

Real-Time Intelligence

Dynamic dashboards with pie charts, bar graphs, scatter plots and live alerts ensure you're always in control of your operations.

04

Proven ROI

Energy cost reduction, downtime prevention, and safety compliance translate directly to measurable bottom-line improvements.

Our Impact

Delivering Measurable Results

Numbers that reflect the real value we create for our industrial clients across India.

↓23%

Energy Cost Reduction

+ 90%

System Accuracy Achieved

Zero

Safety Incidents at Monitored Sites

25+

Solutions Deployed

Ready to Digitize Your
Industrial Operations?

Let's discuss how Ecoloop can build a custom solution for your plant. We're based in India and serve clients across the Globe.

Send Us a Message +91 8103661072

Get In Touch

Let's Build
Something Smart

Have a challenge in your plant? Whether it's Process Moitoring & Control, Quality Control, Safety monitoring, Energy management or Eequipment health — we'd love to hear about it and propose a solution.

Address

114, Street 28, Smriti Nagar
Bhilai 490020, Chhattisgarh, INDIA

Phone

+91 8103661072

Email

info@ecoloop.in

Send a Message

Your Name

Company

Email Address

Area of Interest

Message

Domain Overview

Computer Vision

Turn every camera into a 24×7 intelligent inspector — detecting PPE violations, measuring hot lengths, profiling temperatures, and triggering PLC actions in real time across your plant.

11

PPE Types Trained

3

Sub-Domains

24×7

Monitoring

Safety Applications of Computer Vision

"Safety is critical in industry. It is related to human behaviour and needs vigilant monitoring and preventive checks." Ecoloop's CV safety solutions turn cameras into automated safety guards with real-time PLC interlocks.

🦺

PPE Adherence — Arc Flash Suit

Trained on 11 types of LT & HT Arc Flash Suits. Deployed in major steel and aluminium plants. Real-time dashboard alerts and email/SMS notifications on non-compliance.

Steel PlantsAluminiumHT Systems

🚷

Human Presence Detection — Hazardous Zones

Tracks persons moving in/out of safe and unsafe zones at Blast Furnace Cast House. Hardware-interfaced to stop Mudgun or Drill Machine automatically to prevent fatal accidents.

Blast FurnaceCast HousePLC Interlock

🔥

Fire & Smoke Detection

AI-based detection in electrical rooms and cable galleries. Triggers alarms and suppression interlocks. PoC completed for electrical rooms — no manual inspection needed.

Electrical RoomsCable Galleries

🚛

360° Eye — Heavy Vehicles

style="text-align:justify"4-direction camera watchdog for Wheel Loaders and Excavators. Alerts both driver and nearby workers. Prevents collisions in busy mine and plant areas.

MiningExcavatorsWheel Loaders

🏗️

Crane Load Zone Watch

Monitors the area beneath hanging crane loads. Real-time alerts to crane operator and can stop crane movement when the danger zone is breached.

CranesPLC Interlock

🏭

Stack & Flare Monitoring

Visual stack smoke detection triggers process corrections. Thermal Flare Stack Monitoring ensures constant flaring at Blast Furnaces — critical CO gas safety.

Blast FurnaceCO SafetyThermal

✅ Multi-Algorithm Single Camera Deployment

The same camera can run multiple AI algorithms simultaneously — PPE, human detection, fire, process — on a single real-time feed. Dramatically reduces hardware cost while maximising coverage. All solutions interface with conventional DCS/PLC for closed-loop control actions.

Process Control & Yield Improvement

"Yield is the buzzword in industry." Ecoloop's process control CV solutions directly reduce material losses at SMS, Rolling Mills, Pellet plants, and RMHS — with closed-loop PLC integration.

⚙️ Steel Melting Shop (SMS)

📐

Billet / Bloom Cut-to-Length — Visual Camera

Measures hot lengths at caster in real time. Applies shrinkage compensation and issues cut commands to auto cutter. Supports multiple cut lengths per heat, per strand.

SMS CasterAuto CutterMulti-Strand

🌡️

Billet / Bloom Cut-to-Length — Thermal Camera

For alloy steel with large sections or sticky scale. Thermal camera overcomes limitations of visual systems in cooled or scaled cut areas.

Alloy SteelThermal CameraLarge Sections

🏗️ Rolling Mills

✂️

Shear Head Cut Length Measurement

Head and tail cut lengths measured in real time at the shear. Results available before next billet rolls in — enabling immediate in-process correction.

ShearYield Improvement

📏

Hot Length Measurement & Precise Cut-to-Length

Camera-based hot length of every rolled product. Optimises saw placement and ensures customer-specified lengths. Shrinkage compensation built in.

Cooling BedSaw Control

🔖

Virtual ID — Material Tracking

Each rolled piece gets a unique Virtual ID that propagates through all downstream cuts. Detects manual lifts that conventional PLC tracking systems miss entirely.

Material TrackingTraceability

🔩 Pellet, Sinter & RMHS

🔩

Missing Grates, Wheels & Parts

AI monitors every Pellet/Sinter car rotation for missing grates, wheels, rollers, and seals. Pre-defined alert levels trigger maintenance before quality is impacted.

Pellet PlantSinter Plant

⛏️

Coal Oversize Detection

RMHSBelt Speed 4 m/s

🎗️

Conveyor Belt Defect Detection

Continuous monitoring for joints, cuts, holes, and tearing in conveyor belts. Early detection prevents catastrophic belt failures and unplanned stoppages.

ConveyorBelt Health

Thermal Imaging Solutions

Thermal cameras see what visual cameras cannot — temperature distributions, cooling patterns, and heat signatures in demanding industrial environments.

🧱

Cooling Bed Temperature Profile

Temperature monitored versus time on the cooling bed to study cooling behaviour and correlate to material properties. Identifies deviations that affect structural quality.

Rolling MillMaterial QualityTime-Temp Profile

🔧

Bearing Temperature Monitoring

Continuous thermal monitoring of critical rotating equipment bearings. Trending data enables predictive maintenance scheduling and prevents unplanned breakdowns.

Predictive MaintenanceRotating Equipment

🌊

Layer-wise Thermal Profiling — Sinter/Pellet

Discharge-end profiling across multiple layers and zones. Complete temperature map identifies localised car defects and generalised process deviations.

Pellet PlantSinter PlantMulti-layer

🔥

Flare Stack Monitoring

Ensures the flare stack is always lit — preventing CO gas accumulation at Blast Furnaces. Critical safety requirement deployed as a 24×7 thermal camera system.

Blast FurnaceCO Safety24×7

Domain Overview

Industrial IoT

Connect every PLC, sensor, and machine into a unified monitoring fabric — delivering real-time visibility, predictive maintenance, energy intelligence, and digital safety across your plant.

4

Sub-Domains

OT

IT-OT Isolated

Cloud

Ready

IIoT Safety Solutions

Digital safety systems that move beyond clipboards and physical padlocks — providing verified, traceable, hardware-interlocked maintenance safety for every equipment shutdown.

🔒

e-LOTO++ — Digital Lockout-Tagout

Centralised digital control with individual user accounts, digital signatures, and a complete audit trail. Integrates with equipment PLCs for hard interlocks. Remote access enables multi-site collaboration.

PLC InterlockAudit TrailDigital Signatures

🚦

Unmanned Crossing Monitoring

IoT-based monitoring of unmanned rail or vehicle crossings within plant. Automated alerts and barrier control to prevent accidents at unattended intersections.

Rail SafetyAutomated

🔐 Why e-LOTO++ Outperforms Conventional LOTO

Conventional LOTO relies on physical locks and paper permits — prone to human error, missing audit trails, and no remote oversight. e-LOTO++ delivers real-time compliance monitoring, digital accountability, and hardware-level equipment interlocks — all from a centralised dashboard accessible anywhere.

Remote Monitoring Solutions

Real-time access to all process parameters, utility systems, and field assets — without leaving the control room. Predictive maintenance, remote diagnostics, and data-driven optimisation.

🏭 PLC / DCS Parameters

🎛️

PLC / DCS Remote Monitoring

Monitor Temperature, Pressure, Flow, Energy, Power, Voltage, Current, Vibration, Speed in real time. IT-OT isolation hardware. PLC-to-ERP/SAP data interface. Predictive maintenance via pattern analytics.

TemperaturePressureVibrationIT-OT Isolated

🟢

Belt Switch Monitoring

All belt switches and push buttons individually addressed and monitored at the control room. Fast fault localisation reduces conveyor downtime restoration time significantly.

ConveyorRMHS

⚡ Utilities & Infrastructure

💧

Pump Houses, Sub-Stations & Utilities

Motors, valves, flow meters, tank levels, transformer parameters — all monitored centrally. Deployed for Railway pump houses on cloud. Predictive maintenance and remote troubleshooting.

Pump HousesSub-StationsCloud

⚡

Energy Monitoring System

Centralised monitoring of Electrical Power, Compressed Air, Gas, and Water. Consumption pattern analysis for load shifting, tariff reduction, and Kobetsu Kaizen energy projects. Modbus/TCP-IP.

PowerAirGasWater

⚖️

Heavy Earth Movers

Hydraulic weighing system for Wheel Loaders, Cranes, and Trucks provides real-time payload data. Trip counts, daily tonnage, shift-wise production data captured automatically.

Wheel LoadersTrucksWeighment

Equipment Health Monitoring

Continuous monitoring of critical assets — Ladle Cars, Torpedo Cars, Cranes, Motors, and Conveyors — transforming maintenance from reactive to predictive.

🏭

Ladle & Torpedo Car Monitoring

Monitor lining temperatures, wheel conditions, car movements, and refractory wear. Dashboard and alarm systems ensure timely refractory repair to prevent breakouts.

Steel PlantRefractoryBreakout Prevention

🏗️

Crane Health Monitoring

Crane motor currents, hoist rope condition, travel limits, brake wear, and load cells — all monitored continuously with threshold-based alerts and trending.

Overhead CraneMotor Health

⚡

Motor Health — Vibration & MCSA

Vibration, temperature, and current signature analysis (MCSA) for critical motors. Identify bearing failure, rotor imbalance, and insulation degradation proactively.

VibrationMCSABearing Health

🎗️

Conveyor Belt Health

Individual pull-chord switches, belt sway sensors, and stop push-button monitoring. All belt switches individually addressed for fast fault localisation and reduced restoration time.

Belt SwayPull ChordFast Restoration

IoT Platform & Solutions

A cloud/intranet-enabled platform for device management, data ingestion, analytics, and alerting — plus QR/RFID asset tracking and custom industrial controllers.

☁️

IoT Cloud Platform

Network of physical devices with sensors sharing data over internet or intranet. Centralised platform for device management, analytics, dashboard creation, and alerting — customisable for each plant.

CloudIntranetCustomisable

🏷️

QR / RFID Asset Tracking

Real-time location, custody chain, and usage history for tools, equipment, Prducts, and spare parts. Improves Process Efficiency, Eliminates asset loss and improves maintenance spare planning.

QR CodeRFIDAsset Management

⚙️

Batch Controllers

Custom controllers for special-purpose batch control, testing, and calibration — including Crane Magnet Calibration systems. Precise, repeatable control sequences for industrial processes.

Batch ControlCalibrationCustom

🏋️

Weigh Feeder Controller

Precision feed rate control for raw materials or finished products. Purpose-built controllers integrating with existing DCS/PLC infrastructure for process industries.

Weigh FeederDCS Integration

🏗️

Steel Plants

Integrated steel from BF to Rolling Mill

BF Cast House — Human Detection, CO Safety

SMS — Billet Cut-to-Length (Visual + Thermal)

Rolling Mill — Head Cut, Hot Length, Virtual ID

Arc Flash PPE Adherence at HT Systems

Ladle, Torpedo & Crane Health Monitoring

e-LOTO++, Energy Monitoring System

⛏️

Mining & RMHS

Open-cast mining and raw material handling

Coal Oversize Detection at 4 m/s Belt Speed

Conveyor Defect Detection (joints, cuts, holes)

Pellet/Sinter Machine Health (gates, wheels)

360° Eye for Excavators & Wheel Loaders

Heavy Mover Weighment & Dispatch Analytics

Belt Switch Monitoring

⚡

Power & Utilities

Power plants and utility infrastructure

Energy Monitoring — Power, Air, Gas, Water

Sub-Station Remote Monitoring

Pump House @ Cloud (Railway & Industrial)

DG Set & Compressor Controller

Load Shedding & Tariff Optimisation

🏚️

Cement & Process

Cement plants and continuous process industries

Stack Smoke Detection & Emission Monitoring

Conveyor Belt Defect Detection

PLC Remote Monitoring for Kiln & Mill

Belt Switch Monitoring

🏥

Medical IoT

Healthcare and patient monitoring

Patient Remote Monitoring

Custom Medical IoT Gadgets

IoT-based Diagnostics Support

Solution Matrix

Which Solution for Which Industry?

IIoT and Computer Vision solutions are often deployed together for maximum impact.

Solution	🏗️ Steel	⛏️ Mining	⚡ Power	🏚️ Cement
PPE Adherence (CV)	✔	✔	✔	✔
Human Hazard Zone Detection (CV)	✔	✔	—	—
Billet/Bloom Cut-to-Length (CV)	✔	—	—	—
Coal Oversize / Conveyor Defects (CV)	✔	✔	—	✔
Thermal Profiling (CV)	✔	✔	—	—
e-LOTO++ (IIoT)	✔	✔	✔	✔
PLC/DCS Remote Monitoring (IIoT)	✔	✔	✔	✔
Energy Monitoring System (IIoT)	✔	✔	✔	✔
Equipment Health Monitoring (IIoT)	✔	✔	✔	✔

Company Profile

At Ecoloop, we are a dynamic and forward-thinking tech startup specialising in engineering and development, focused on enhancing Quality of Life with "Ideas to Innovations" as our driving force.

Our team of seasoned professionals brings a wealth of experience in electrical and electronics, with a primary focus on IoT and Image Processing. Our mission is to bring positive change to industry, medical health services, building automation, and energy conservation.

We leverage the power of IoT and image processing technologies to revolutionise businesses across diverse sectors. Through customised IoT solutions, we empower organisations to optimise operations, increase efficiency, and maximise resource utilisation. Advanced image processing algorithms enable intelligent analysis of visual data.

Ecoloop collaborates closely with industrial enterprises to deliver innovative solutions including remote monitoring, predictive maintenance, and process optimisation. Our industrial exposure and deep understanding of different processes helps design optimised, customised solutions that deliver measurable ROI.

IIoT

Industrial Internet of Things

CV / AI

Computer Vision & AI/ML

Board Members

Rajnish J Shivram

Director / Ecoloop

MBA – IIM Raipur Alumni, B.E. Electronics. 30+ years in Process Automation, Concept Design, and Energy Conservation. Deep industrial exposure drives customised, optimised solution design.

B Hari Kishor Rao

Director / Ecoloop

B.E. Mechatronics. 16+ years in Electronics Product Design, Assembly, and Development. Core strength in hardware/backend development and meticulous project execution.

Our Edge : Combined expertise in Process Automation + Electronics Product Design + AI/ML enables complete, closed-loop industrial solutions — from sensor to cloud to action.

🦺

PPE Adherence — Arc Flash Suit

Detects if personnel operating HT systems are wearing Arc Flash Suits. Trained on 11 types of LT and HT Arc Flash Suits. Deployed in major steel and aluminium plants. Generates dashboard alerts and email/SMS notifications on non-compliance.

Steel PlantsAluminiumHT Systems

🚷

Human Presence Detection — Hazardous Zones

Sophisticated algorithms detect and track human presence in areas like the Blast Furnace Cast House. Tracks persons moving in/out of safe and unsafe zones. Interfaced with hardware to automatically stop Mudgun or Drill Machine operations to prevent fatal accidents.

Blast FurnaceCast HousePLC Interlock

🔥

Fire & Smoke Detection

AI-based fire and smoke detection in electrical rooms, cable galleries, and process areas replaces manual inspections. Triggers alarms and can initiate suppression system interlocks. PoC completed for electrical rooms.

Electrical RoomsCable Galleries

🚛

360° Eye — Heavy Vehicles

4-direction camera watchdog for Wheel Loaders, Excavators, and Heavy Vehicles. Provides real-time alerts to both the driver and nearby workers. Prevents collision with personnel and structures in busy mine/plant areas.

MiningExcavatorsWheel Loaders

🏗️

Crane Load Zone Watch

Camera-based alert system monitors the area beneath hanging crane loads. Provides real-time alerts to the crane operator and can stop crane movement automatically when the danger zone is breached.

CranesSteel PlantPLC Interlock

🏭

Stack & Flare Monitoring

Camera-based stack monitoring detects unwanted smoke emissions and triggers process control corrections. Thermal camera-based Flare Stack Monitoring ensures the stack is always lit — especially at Blast Furnaces where CO gas safety is critical.

Blast FurnaceCO SafetyThermal Camera

✅ Multi-Algorithm Single Camera Deployment

The same camera can run multiple AI algorithms simultaneously — monitoring PPE, human presence, fire, and process parameters concurrently on a single real-time video feed. This dramatically reduces hardware cost while maximising coverage. All solutions interface with conventional DCS/PLC systems for closed-loop control actions, with email/dashboard notifications ensuring compliance.

✂️

Shear Head Cut Length Measurement

Head and tail cut lengths measured in real time at the shear. Precise measurement minimises material loss and improves yield. Results available before the next billet rolls in — enabling in-process correction and optimisation.

ShearYield ImprovementHot Measurement

📏

Hot Length Measurement

Hot length of every rolled product measured by camera to optimise cut lengths and control saw placement. Provides reliable estimates for real-time correction of cutting parameters. Works at belt speed in hot, dusty environments.

Cooling BedSaw ControlReal-Time

📌

Precise Cut Lengths — Short Length Prevention

In alloy steel production, customers specify fixed cut lengths with minimal tolerance. Camera-based hot measurement ensures every piece meets spec. Shrinkage compensation and auto-cutter release commands are integrated.

Alloy SteelCut-to-LengthPLC Interlock

🔖

Virtual ID — Material Tracking

Each rolled piece receives a unique Virtual ID that travels through all downstream processes. When material is further cut, new related IDs are propagated automatically. Acts as a visual verification layer over PLC-based tracking — even detecting manual lifts that conventional systems miss.

Material TrackingTraceabilityCooling Bed

🔗 Closed-Loop PLC Integration

Mill solutions interface directly with existing PLC/DCS systems. Detection triggers auto-cutter corrections, home position adjustments, and clamp controls. A menu-driven recipe system allows operators to enter cut lengths, quality cut lengths, and compensation parameters via an intuitive dashboard with state-of-art visualisation, monitoring, recording, and analysis.

📐

Billet / Bloom Cut-to-Length — Visual Camera

Measures hot billet/bloom lengths at the caster in real time. Applies shrinkage compensation and issues precise cut commands to the auto cutter. Supports multiple cut lengths in a single heat and per-strand length allocation. Compensates for cutter mechanical home position and clamp corrections.

SMS CasterAuto CutterMulti-Strand

🌡️

Billet / Bloom Cut-to-Length — Thermal Camera

Thermal camera solutions for alloy steel with large cross-sections where the cut area cools significantly. Also handles sticky scale formation that confuses visual-based systems. Ideal for high-alloy grades requiring precision.

Alloy SteelThermal CameraLarge Sections

🖥️

State-of-Art SMS Dashboard

Comprehensive dashboard for real-time monitoring, recording, and analysis. Menu-driven recipe entry for cut length, quality cut lengths, and all compensation parameters. Visualisation, alarm management, and historical data in one interface.

DashboardRecipe ManagementData Logging

🔩

Missing Grates Detection

AI tracks missing grates and gaps in each Pellet or Sinter car on every rotation. Data stored and monitored against pre-defined alert thresholds. Prevents gaps from degrading product quality.

Pellet PlantSinter Plant

🌡️

Discharge-Side Thermal Profiling

Thermal profiling of the Pellet/Sinter bed at the discharge end monitors temperature across layers and zones. Reveals localised car defects and generalised system issues for targeted corrective action.

Thermal CameraBed Temperature

⚙️

Missing Wheels, Rollers & Parts

Machine components like wheels and rollers monitored on every rotation for presence and condition. Historical data enables life-cycle studies and proactive replacement planning before failure.

Predictive MaintenanceLife-Cycle

🪟

Missing Seals & Wall Monitoring

Real-time monitoring of all seals and walls. Seal failures detected immediately, preventing quality and production losses that typically go unnoticed until major breakdown.

Sealing IntegrityReal-Time

⛏️

Coal Oversize Detection (RMHS)

Detects and measures oversize coal on conveyor belts at 4 m/s belt speed even in dusty environments. Triggers crusher control actions to reduce oversize material and prevent crusher blockages.

RMHSBelt Speed 4 m/sCrusher Control

🎗️

Conveyor Defect Detection

Continuous monitoring of conveyor belts for joints, cuts, holes, and tearing. Early detection prevents catastrophic belt failures and unplanned production stoppages.

ConveyorBelt HealthPreventive

📊 Dashboard, Reports, Trends, Alarms

The dashboard approach — missing in conventional control systems — gives data interpretation from collected data, enabling decisive action. Reports, Trends, and Alarms support analysis when pattern study is required. This 24×7 monitoring tool acts as a defect identification and life-cycle analysis engine.

🧱

Product Temperature Profile — Cooling Bed

Cooling pattern plays a vital role in material structure and physical properties. Temperature monitored versus time on the cooling bed to study controlled vs. natural cooling behaviour and analyse material properties. Product defects — both physical and structural — can be correlated to cooling anomalies.

Rolling MillMaterial QualityTime-Temp Profile

🔧

Bearing Temperature Monitoring

Continuous thermal monitoring of bearings on critical rotating equipment enables early detection of overheating — a leading indicator of bearing failure. Provides trending data for predictive maintenance scheduling and prevents unplanned breakdowns.

Predictive MaintenanceRotating Equipment

🌊

Layer-wise Thermal Profiling — Sinter/Pellet

Discharge-end thermal profiling of sinter/pellet beds across multiple layers and temperature zones. Provides a complete temperature map to identify localised car defects and generalised process deviations affecting product quality.

Pellet PlantSinter PlantMulti-layer

🔥

Flare Stack Monitoring

Thermal camera ensures the flare stack is always lit and burning, creating a safe working zone by preventing CO gas accumulation. Particularly deployed at Blast Furnaces where carbon monoxide monitoring is a critical safety requirement.

Blast FurnaceCO Safety24×7

🎛️

Centralised Control & Monitoring

Authorised personnel can oversee all lockout-tagout procedures in real-time through digital platforms. Immediate intervention capability and improved safety management — no more clipboard-based guesswork on the shop floor.

Real-TimeDashboard

✍️

Digital Signatures & Audit Trail

Individual user accounts with digital signatures create a complete, traceable record. Every action is attributed to a specific person, ensuring procedure compliance and providing regulatory-grade traceability.

Audit TrailCompliance

📄

Electronic Documentation

Eliminates manual paperwork. Procedures, instructions, and records stored and accessed digitally. Simplifies regulatory reporting and removes documentation errors from the safety management chain.

PaperlessRegulatory

⚙️

Equipment Integration & Interlocks

Integrates directly with machinery and equipment, adding digital interlock layers. Machines cannot be started while e-LOTO is active, providing a hard safety barrier backed by software and hardware.

PLC InterlockHard Safety

🔔

Real-Time Alerts & Notifications

Instant alerts to supervisors and safety officers on any non-compliance or unsafe condition. Minimises accident potential by ensuring no maintenance work begins without complete lockout verification.

AlertsSMS/Email

🌐

Remote Access & Multi-Site Collaboration

Remote access to LOTO procedures for multi-location organisations. Experts and supervisors guide maintenance remotely without site visits. Particularly valuable during emergencies requiring rapid coordination.

RemoteMulti-Site

Connect Your OT to Actionable Intelligence

Remote monitoring of PLC/DCS parameters transforms raw automation data into operational intelligence. Monitor all key process variables in real time from anywhere.

✓Continuous monitoring of all key process variables
✓Predictive maintenance via pattern analysis
✓Remote troubleshooting — eliminates site visits
✓Long-term statistical data storage and analysis
✓IT-OT LAN isolation hardware for cybersecurity
✓PLC-to-ERP/SAP data interface

TemperaturePressureFlow RateVibrationSpeedEnergy

🏭 Pump House @ Cloud — Railway

All analog and digital controls — motors, valves, flow meters, tank levels — monitored on third-party cloud for Railway pump houses.

🔗 PLC–ERP Interface

Analog and digital data transferred from PLC to ERP through hardware that isolates the IT-OT LAN network — enabling data integration without compromising OT security.

🟢 Belt Switch Monitoring

All belt switches and push buttons individually addressed and monitored at the control room, reducing fault localisation and downtime restoration time significantly.

👁️

Real-Time Visibility & Control

Proactive management of critical infrastructure with timely response to issues. Minimise downtime, reduce maintenance costs, and maximise operational efficiency across all plant utilities.

Real-TimeProactive

🔮

Predictive Maintenance

Sensors and IoT devices collect continuous data that analytics algorithms monitor for failure signatures. Take preventive action before failures escalate — optimise maintenance schedules and extend equipment lifespan.

AnalyticsPreventive

🛠️

Remote Troubleshooting

Experts remotely access the system, analyse parameters, and make necessary adjustments — no site visits required. Significantly reduces response time and minimises disruptions to production.

Remote AccessFast Response

📊

Comprehensive Data Analytics

Gain valuable insights into energy usage, operational patterns, and performance trends. Data-driven decision-making enables improved energy efficiency and optimised resource allocation.

AnalyticsEnergy Efficiency

Covered Assets

Pump Houses (motors, valves, flow meters, tank levels) · Sub-Stations (transformer parameters, bus voltages, feeder currents) · Compressors · DG Sets · Gas Stations · Water Treatment Utilities

Take Control of Your Energy Costs

Track usage against design capacities across all energy vectors. Consumption pattern monitoring helps shift load operations to non-peak hours, reducing overall tariff charges.

✓Consumption pattern monitoring for load shifting
✓Shift loads to non-peak hours — reduce tariff
✓Informed load shedding during power stoppage
✓Air, Gas, and Water cost monitoring
✓Data for Kobetsu Kaizen energy projects
✓Modbus / TCP-IP protocol support

Electrical PowerCompressed AirGasWater

📈 Dynamic Dashboard Visualisation

Responsive dashboards with widgets including Pie Charts, Bar Graphs, Area Graphs, and Scatter Plots for intuitive energy data visualisation and pattern analysis.

⚡ Load Shedding Support

During power stoppage or restoration, the EMS enables informed, priority-based load shedding and restoration decisions — eliminating guesswork and protecting critical processes.

🔗 Protocol Support

Energy parameters acquired through Modbus or TCP-IP — compatible with most energy meters and smart meters already installed in the plant.

⚖️

Hydraulic Weighing System

Heavy earth movers including Wheel Loaders, Cranes, and Trucks get real-time payload weighment. Prevents overloading, enables accurate material tracking, and supports production and dispatch reporting.

Wheel LoadersCranesTrucks

📡

Remote Health Monitoring

Equipment health parameters — fuel consumption, cycle times, hydraulic pressure, engine temperature — monitored remotely for data collection and analytics. Enables operator performance analysis and predictive maintenance.

Health MonitoringPredictive

📊

Production & Dispatch Analytics

Trip counts, load per trip, daily tonnage, and shift-wise production data captured automatically. Eliminates manual tallying and provides accurate material movement records for dispatch and inventory management.

Production DataAnalytics

🏭

Ladle & Torpedo Car

Monitor lining temperatures, wheel conditions, car movements, and refractory wear on ladles and torpedo cars. Dashboard and alarm systems ensure timely refractory repair to prevent breakouts and production loss.

Steel PlantRefractoryBreakout Prevention

🏗️

Crane Health Monitoring

Monitor crane motor currents, hoist rope condition, travel limits, brake wear, and load cells. Prevent catastrophic crane failure through continuous health trending and threshold-based alerts.

Overhead CraneMotor Health

⚡

Motor Health Monitoring

Vibration, temperature, and current signature analysis (MCSA) for critical motors. Identify bearing failure, rotor imbalance, and insulation degradation before they cause unplanned shutdowns.

VibrationMCSABearing Health

🎗️

Conveyor Belt Health

Individual pull-chord switches, belt sway sensors, and stop push-button monitoring. All belt switches individually addressed and monitored at the control room for fast fault localisation and downtime reduction.

Belt SwayPull ChordFast Restoration

☁️

IoT Cloud Platform

A network of physical devices embedded with sensors that collect and share data over internet or intranet. Centralised platform for device management, data ingestion, analytics, dashboard creation, and alerting — customisable for each plant.

CloudIntranetCustomisable

🏷️

QR / RFID Asset Tracking

Physical assets — tools, equipment, refractory materials, spare parts — tracked with QR codes or RFID tags. Real-time location, custody chain, and usage history on dashboard. Eliminates asset loss and improves maintenance spare planning.

QR CodeRFIDAsset Management

⚙️

Batch Controllers

Custom controllers for special-purpose batch control, testing, and calibration equipment — including Crane Magnet Calibration systems. Purpose-built for industrial processes that demand precise, repeatable control sequences.

Batch ControlCalibrationCustom

🏋️

Weigh Feeder Controller

Precision weigh feeder control for accurate feed rates of raw materials or finished products. Purpose-built controllers integrating with existing DCS/PLC infrastructure for process industries.

Weigh FeederRaw MaterialDCS Integration

👁️ Computer Vision Solutions

Blast Furnace

Human Presence Detection at Cast House with PLC interlock on Mudgun/Drill Machine. Thermal Flare Stack Monitoring for CO safety. Arc Flash PPE adherence at HT systems.

Steel Melting Shop (SMS)

Billet/Bloom Cut-to-Length using Visual & Thermal cameras. Multiple cut lengths in single heat. Auto-cutter integration with shrinkage compensation.

Rolling Mill

Shear Head Cut measurement, Hot Length measurement, Precise cut-to-length, Virtual ID material tracking — all with closed-loop PLC correction.

📡 Industrial IoT Solutions

Equipment Health

Ladle & Torpedo Car monitoring. Crane health. Motor vibration & temperature. Conveyor belt health — pull chords, belt sway, and push buttons.

Safety — e-LOTO++

Digital Lockout-Tagout for safe maintenance of all critical equipment — with PLC interlock, digital audit trail, and remote collaboration.

Energy & Utilities

Energy Monitoring System for Electrical Power, Compressed Air, Gas, and Water. Sub-Station and Utility Remote Monitoring.

⛏️

Coal Oversize Detection

AI detects and measures oversize coal at 4 m/s belt speed in dusty environments. Controls crusher to prevent blockages and reduce downstream equipment damage.

Computer VisionRMHS

🎗️

Conveyor Belt Defect Detection

Detects joints, cuts, holes, and tearing in conveyor belts in real time. Prevents catastrophic belt failures and enables planned maintenance replacement.

Computer VisionConveyor

🚛

360° Eye for Excavators

4-camera alerting system for Excavators and Wheel Loaders. Warns both driver and nearby workers of proximity dangers. Prevents accidents in busy mine working areas.

Computer VisionSafety

⚖️

Heavy Mover Weighment

Real-time hydraulic weighing system for Wheel Loaders and Dump Trucks provides accurate payload data for production and dispatch management.

IIoTDispatch

🔩

Pellet/Sinter Machine Health

Missing grates, wheels, seals, and parts detected on every rotation. Thermal profiling at discharge end. Life-cycle data collection for planned maintenance.

Computer VisionPredictive

📡

Belt Switch Monitoring

All belt switches and push buttons individually addressed and monitored at the control room. Fast fault localisation reduces downtime restoration significantly.

IIoTRMHS

⚡

Energy Monitoring System

Monitor Electrical Power, Compressed Air, Gas, and Water centrally. Analyse consumption patterns, shift loads to off-peak periods, and take data-driven decisions for load shedding.

IIoT

🏭

Sub-Station Remote Monitoring

Real-time monitoring of transformer parameters, bus voltages, feeder currents, and protection relay status from a central control interface.

IIoT

💧

Pump House Monitoring

All analog and digital controls — motors, valves, flow meters, tank levels — monitored in real time. Deployed for Railway and industrial pump house applications on cloud platforms.

IIoTCloud

🔧

DG & Compressor Controller

Custom controllers for DG sets and compressors with remote monitoring, parameter logging, and automated start/stop control. Ensures uninterrupted auxiliary power supply.

IIoTCustom

🏭

Stack Smoke Detection

Camera-based stack monitoring detects unwanted emissions and triggers process control corrections or compliance notifications automatically.

Computer VisionEmissions

🎗️

Conveyor Health

Belt defect detection, belt switch monitoring, and conveyor health monitoring — reducing downtime in raw material handling and finished product dispatch operations.

Computer VisionIIoT

📡

PLC Remote Monitoring

Remote monitoring of key process parameters across kilns, mills, and utilities with centralised dashboard, alarms, and data logging for informed maintenance decisions.

IIoT

🩺

Patient Remote Monitoring

IoT-enabled remote monitoring solutions allow healthcare providers to track patient vitals continuously. Supports better diagnostics and improved patient outcomes through data-driven healthcare delivery.

HealthcareIoT

🔬

Computer Vision

Sugar Bag Counting

@ Triveni Sugars

Computer Vision Food

Sugar Bag Counting

Triveni Sugars

Computer Vision

Rolling Mill Process Control

@ Avtar Steel

Computer Vision Steel Plant

Rolling Mill Process Control

Avtar Steel

🎬

Demo Videos are sent on request

Short demonstration videos of each deployed solution — showing live detections, dashboards in action, and real process results on request.

Get in Touch

Let's Build Something Together

Tell us about your challenge. Our team will design a customised solution that fits your process, your plant, and your budget.

Contact Information

📍

Address114, Street 28, Smriti Nagar,
Bhilai 490020, Chhattisgarh, India

📞

Phone+91 81036 61072 | +91 910911 8460

✉️

Emailinfo@ecoloop.in

🌐

Websitewww.ecoloop.in

🕒 Working Hours

Monday – Saturday: 9:00 AM – 6:00 PM IST

Send Us a Message

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Computer Vision andIIoT Solutions

Two Pillars of Industrial Intelligence

Industrial IoT

Computer Vision

Purpose-Built for Your Industry

Remote Monitoring & Control at Your Fingertips

Cameras That Work as Hard as Your Workers

Your Innovation Partner

Delivering Measurable Results

Ready to Digitize YourIndustrial Operations?

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Computer Vision

Safety Applications of Computer Vision

PPE Adherence — Arc Flash Suit

Human Presence Detection — Hazardous Zones

Fire & Smoke Detection

360° Eye — Heavy Vehicles

Crane Load Zone Watch

Stack & Flare Monitoring

✅ Multi-Algorithm Single Camera Deployment

Process Control & Yield Improvement

⚙️ Steel Melting Shop (SMS)

Billet / Bloom Cut-to-Length — Visual Camera

Billet / Bloom Cut-to-Length — Thermal Camera

🏗️ Rolling Mills

Shear Head Cut Length Measurement

Hot Length Measurement & Precise Cut-to-Length

Virtual ID — Material Tracking

🔩 Pellet, Sinter & RMHS

Missing Grates, Wheels & Parts

Coal Oversize Detection

Conveyor Belt Defect Detection

Thermal Imaging Solutions

Cooling Bed Temperature Profile

Bearing Temperature Monitoring

Layer-wise Thermal Profiling — Sinter/Pellet

Flare Stack Monitoring

Industrial IoT

IIoT Safety Solutions

e-LOTO++ — Digital Lockout-Tagout

Unmanned Crossing Monitoring

🔐 Why e-LOTO++ Outperforms Conventional LOTO

Remote Monitoring Solutions

🏭 PLC / DCS Parameters

PLC / DCS Remote Monitoring

Belt Switch Monitoring

⚡ Utilities & Infrastructure

Pump Houses, Sub-Stations & Utilities

Energy Monitoring System

Heavy Earth Movers

Equipment Health Monitoring

Ladle & Torpedo Car Monitoring

Crane Health Monitoring

Motor Health — Vibration & MCSA

Conveyor Belt Health

IoT Platform & Solutions

IoT Cloud Platform

QR / RFID Asset Tracking

Batch Controllers

Weigh Feeder Controller

Purpose-Built for Every Industry

Steel Plants

Mining & RMHS

Power & Utilities

Cement & Process

Medical IoT

Which Solution for Which Industry?

Dynamic. Forward-Thinking.Customer-First.

Company Profile

Board Members

Image Processing for Industrial Safety

PPE Adherence — Arc Flash Suit

Human Presence Detection — Hazardous Zones

Fire & Smoke Detection

360° Eye — Heavy Vehicles

Crane Load Zone Watch

Stack & Flare Monitoring

✅ Multi-Algorithm Single Camera Deployment

Image Processing in Rolling Mills

Computer Vision
and
IIoT Solutions

Ready to Digitize Your
Industrial Operations?

Let's Build
Something Smart

Dynamic. Forward-Thinking.
Customer-First.