Intelgic has successfully implemented an AI-powered camera-based counting solution at DCM Shriram Limited, one of India’s most renowned sugar manufacturers. The deployment enables real-time, highly accurate counting of sugar bags moving through conveyor systems—addressing long-standing challenges in manual and semi-automated counting at high throughput. According to Mr. Dhiraj Gosain, A.G.M. at DCM Shriram Limited, this marks the first time a sugar manufacturing unit has implemented an AI- and camera-based counting system for automated bag counting.
Seamless integration with existing surveillance cameras
The solution connects directly to the mill’s existing surveillance camera infrastructure, eliminating the need for specialized hardware changes. Intelgic’s AI software ingests the live video stream in real time, processes frames on the edge, and delivers instant bag counts without interrupting production.
Accurate counting—even with overlapping and stacked bags
A key challenge in sugar mills is bags overlapping or stacking on conveyors, which often leads to undercounts or overcounts with traditional vision rules. Intelgic’s AI model is trained to recognize individual bags even when partially occluded, maintaining accuracy across varying conveyor speeds, lighting conditions, and bag arrangements.
Real-time visibility and operational transparency
Operators and supervisors gain live counting metrics, time-stamped events, and shift-wise totals, enabling:
- Reliable dispatch and inventory reconciliation
- Faster issue identification during loading/unloading
- Reduced dependency on manual checks and paperwork
The system’s real-time outputs also support downstream reporting and audit needs.
Rapid deployment, scalable design
Designed for industrial environments, the solution was deployed quickly and can be scaled across multiple conveyor lines or facilities. Its camera-agnostic architecture allows mills to expand coverage using existing RTSP-enabled cameras while keeping costs controlled.
Driving efficiency and accountability in sugar logistics
By replacing error-prone manual counts with AI-driven automation, the implementation helps improve operational efficiency, accuracy, and accountability—critical factors for high-volume sugar bag handling.
This successful deployment at DCM Shriram Limited reinforces Intelgic’s growing footprint in AI-based industrial counting and monitoring solutions for bulk material handling and logistics-heavy manufacturing sectors.
