Bucket Overfilling Detection Case Study | GHCL

Operations
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Business Impact

  • Monthly Cost Savings
  • Zero Manual Intervention
  • Good Manpower optimization


Customer Facts

Location: India

Industry: Chemical

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Problem Statement

Problems we Acquired

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. Carryover material causes bucket overfeed, resulting in operational stoppages, manual material removal, and a direct impact on the plant's efficiency, environment, and overall process cost.  

Challenges

Obstacles we faced

  • Frequency: 2–3 Incidents/Month
  • Downtime: 1.5 Hours per Incident
  • Fall hazards: Safety Risk
  • Resource Loss : Raw material wastage

Technologies

Tech stack we used

Solution

How we made end solution

  • 7 Cameras Deployed
  • CCTV Integration
  • OT Sync Integrated Tripping
  • Real-time bucket volume monitoring via 7 lines, each camera monitoring one line.
  • Immediate detection of carry-over material after discharge.
  • Automated OT integration to trigger tripping and prevent overfeeding.

Result

Outcome we get

  • 95% Overflow Reduction
  • 95% Downtime Reduction
  • 5% Material Loss Saved