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Category 05

Smart Factory & AI Food Safety Systems

AI GMP monitoring, PPE compliance detection, hygiene monitoring, predictive analytics, real-time risk systems and smart factory sensors — the technology layer that turns your production floor into a continuously monitored, data-driven compliance environment.

AI GMP Monitoring Cameras
AI GMP Monitoring Cameras
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AI Vision

AI GMP Monitoring Cameras

AI-powered GMP (Good Manufacturing Practice) monitoring systems that install directly onto any existing IP or CCTV camera infrastructure via RTSP stream — with no new hardware required in most cases. The AI model runs inference locally on an edge server, continuously analysing camera feeds for GMP non-conformities including missing or incorrect PPE, hygiene procedure violations, unauthorised zone entry and personnel behaviour that conflicts with food safety requirements. Every detection is timestamped, classified and stored, creating a verifiable 24/7 compliance record across every shift without a human auditor present. Unlike periodic audits that capture a snapshot, AI GMP monitoring captures everything, all the time.

Key Features
InstallationExisting IP/CCTV cameras via RTSP stream
ProcessingOn-premise edge server — no cloud video transfer
DetectionPPE, hygiene violations, zone breaches, GMP non-conformities
AlertsReal-time SMS, email and dashboard notification
RecordsTimestamped detection log with image capture
PrivacyGDPR compliant, video stays on-premise
Applications
Food ManufacturingProduction FloorsPacking AreasHigh-Care ZonesClean RoomsHospitality
PPE Compliance Detection Systems
PPE Compliance Detection Systems
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PPE Compliance

PPE Compliance Detection Systems

Dedicated AI detection systems for monitoring Personal Protective Equipment compliance across food production environments. The system recognises the presence and correct use of hairnets, beard snoods, gloves, aprons, dedicated footwear and face coverings — alerting supervisors in real time when a staff member enters a production zone without required PPE or removes PPE during production. PPE non-compliance is one of the most common non-conformities identified during IFS and BRCGS audits, and one of the hardest to control through manual supervision alone. AI PPE monitoring removes the human dependency entirely.

Key Features
PPE Types DetectedHairnets, gloves, aprons, footwear, face coverings
Response TimeDetection and alert within seconds
CoverageMultiple cameras per zone
AlertsSupervisor notification with camera ID and timestamp
RecordsCompliance rate reporting by zone, shift and individual
IntegrationHACCP platforms and HR systems
Applications
Production Entry PointsHigh-Care ZonesProcessing AreasPacking LinesIFS ComplianceBRCGS Compliance
AI Hygiene Compliance Monitoring
AI Hygiene Compliance Monitoring
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Hygiene Monitoring

AI Hygiene Compliance Monitoring

AI vision systems trained to monitor hygiene procedure compliance in food production environments — detecting when required hygiene steps are skipped, performed incorrectly or bypassed under time pressure. The system monitors hand washing and sanitization station usage, cross-contamination events such as touching non-food surfaces and then product, equipment cleaning adherence between product runs and personnel movement between zones without hygiene steps. Hygiene failures that would previously only be discovered during an internal audit or following a contamination event are flagged in real time, when they can still be corrected.

Key Features
DetectionHand wash compliance, cross-contamination, zone hygiene
MonitoringContinuous 24/7 across all configured cameras
AlertsReal-time to supervisors and compliance managers
RecordsTimestamped event log with visual evidence
ReportingHygiene compliance rate by zone, shift and time
IntegrationHACCP and food safety management platforms
Applications
Hand Hygiene ComplianceCross-Contamination PreventionZone Change HygieneHigh-Care AreasAllergen Control
Smart Production Monitoring
Smart Production Monitoring
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Production Intelligence

Smart Production Monitoring

AI-powered production monitoring systems that track operational performance, equipment behaviour and process adherence across the production floor in real time. The system uses existing camera infrastructure to monitor line speeds, equipment utilisation, personnel workflow efficiency and deviation from standard operating procedures — providing production managers with a live view of what is happening on the floor without physically being there. Anomalies in production flow, unexpected stops, equipment misuse and staffing gaps are detected and flagged as they occur.

Key Features
MonitoringLine speed, equipment status, workflow adherence
DetectionAnomalies, stops, misuse, staffing gaps
DashboardReal-time production floor visibility
AlertsConfigurable threshold-based notifications
ReportingShift performance, OEE contribution, trend analysis
IntegrationMES, ERP and SCADA systems
Applications
Production ManagementOEE MonitoringLine EfficiencyEquipment UtilisationShift Management
Predictive Food Safety Analytics
Predictive Food Safety Analytics
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Predictive Analytics

Predictive Food Safety Analytics

Predictive analytics platforms that analyse historical food safety data — CCP monitoring records, corrective action logs, environmental monitoring results, supplier performance data and production parameters — to identify patterns that precede food safety failures before those failures occur. Rather than reacting to non-conformances after the fact, predictive analytics surfaces the leading indicators that signal increased risk, allowing management to intervene proactively. Particularly valuable for facilities with high audit frequency, complex multi-product lines or a history of recurring non-conformances in specific areas.

Key Features
Data SourcesHACCP records, CCP logs, environmental data, supplier data
AnalysisPattern recognition and risk trend identification
OutputRisk scores, leading indicator alerts, intervention recommendations
HorizonConfigurable prediction window
IntegrationDigital HACCP and compliance platforms
ReportingRisk dashboards and management reports
Applications
High-Audit FacilitiesMulti-Product LinesRecurring Non-ConformancesRisk ManagementSenior Management Visibility
Real-Time Risk Monitoring Systems
Real-Time Risk Monitoring Systems
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Risk Monitoring

Real-Time Risk Monitoring Systems

Integrated real-time risk monitoring platforms that aggregate data from across a food safety system — CCP sensors, environmental monitoring results, personnel hygiene compliance, equipment status and production parameters — into a single risk dashboard that gives operations and food safety managers a live view of current risk level across the entire facility. When multiple indicators move in an adverse direction simultaneously, the system raises a composite risk alert before any individual threshold is breached, enabling early intervention. Designed for facilities that want to move from reactive food safety management to continuous, data-driven risk control.

Key Features
Data InputsCCP sensors, environment, hygiene, equipment, production
Risk ModelComposite risk scoring across multiple parameters
DashboardReal-time facility risk level by zone and category
AlertsComposite risk alerts before individual thresholds breach
EscalationConfigurable escalation paths by risk level
ReportingRisk trend history and management reporting
Applications
Multi-Hazard FacilitiesHigh-Risk ProcessingRTE ProductionSenior Management ReportingRegulatory Readiness
Smart Factory Sensors
Smart Factory Sensors
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IoT Infrastructure

Smart Factory Sensors

A range of IoT sensor technologies for food production environments — monitoring temperature, humidity, CO2, differential pressure, vibration, energy consumption and equipment operating parameters in real time. Smart factory sensors form the data collection layer of an integrated food safety and production monitoring system, feeding continuous readings to HACCP platforms, building management systems and production dashboards. Available in food-grade, washdown-rated housings with wireless connectivity options including WiFi, LoRaWAN and NB-IoT for deployment across large or complex facilities without cabling infrastructure.

Key Features
ParametersTemperature, humidity, CO2, pressure, vibration, energy
ConnectivityWiFi, LoRaWAN, NB-IoT, Zigbee
HousingIP65/IP67 food-grade, washdown rated
Battery LifeUp to 5 years depending on model and interval
IntegrationHACCP, BMS and production platforms
CalibrationUKAS-traceable calibration available
Applications
Production EnvironmentsCold RoomsClean RoomsHVAC MonitoringEquipment MonitoringEnergy Management
Production Environment Monitoring
Production Environment Monitoring
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Environment Control

Production Environment Monitoring

Integrated monitoring systems for the continuous measurement of production environment parameters — temperature, humidity, differential pressure, particulate levels and airborne microbial contamination — in food manufacturing facilities. Production environment monitoring is a mandatory requirement in high-care and high-risk food processing areas under IFS and BRCGS standards, and a fundamental element of HACCP hazard control for facilities where environmental conditions directly affect product safety or quality. Systems provide continuous data logging, trend analysis and automated alerts when parameters drift outside defined limits.

Key Features
ParametersTemperature, humidity, differential pressure, particles, microbial
ZonesHigh-care, high-risk, ambient and packaging areas
MonitoringContinuous with configurable alarm thresholds
RecordsAutomated logs for HACCP and audit compliance
AlertsReal-time notification on parameter exceedance
ReportingTrend analysis and compliance reporting
Applications
High-Care ZonesHigh-Risk AreasClean RoomsControlled EnvironmentsRTE ProductionIFS Compliance
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