AI-Material Scan


Detection of foreign objects and particle size analysis in quarries.

A system based on high-resolution industrial cameras and our AI models.

The Challenge

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Mat-Scan-Inferida

01 Automatic detection

Automatic detection of the particle size distribution of gravel and blocks, identifying sizes that exceed specifications and foreign objects that could cause blockages and damage to machinery.

 

02 Blind spots

Current monitoring is based on spot sampling. Results are delayed and not representative of the actual flow.

03 Impact on production

Reprocessing, rejected batches, or corrective blending. Reactive operation. Impact on timelines, costs and compliance.

Advantages

Smart measurement, easy integration

Our system, combined with AI-based analysis, allows us to detect the material in real time, providing detailed information for process control and optimization.


Variables

Granulometry

Real-time detection of large rocks.

Morphology and volume

Estimation of morphology and volume.

Alert
Foreign Objects

Detection of objects or materials that could cause damage or blockages.


Direct integration

Real-time data

Data transmission via standard signals (4–20 mA).

Easy integration

Native integration with existing DCS/SCADA systems. Non-invasive installation.

Visualization

Logging for traceability, quality reports and contractual support.

AI-Material Scan

Monitoring system installed directly on the main production line. Based on industrial machine vision and AI tailored to the monitoring objective.

  • Communication with existing systems

    Continuous system monitoring and immediate alert generation, preventing damage to equipment.

  • Reduction in unplanned downtime

    Control over unplanned downtime and costs associated with corrective maintenance.

  • Scalable system

    A scalable system that can be adapted to different product lines, materials and production.

AI-MATERIAL SCAN

4 keys to optimizing your operations

Optimize operations through continuous data, enabling you to improve efficiency, reduce variability, and make data-driven decisions.

Preventive process control

– Detection of stones and out-of-specification objects before they reach critical points.
– Continuous visibility to anticipate bottlenecks.

Process optimization

– Reduction in unplanned downtime.
– Better process stability in the face of material variability.

Preservation of critical equipment

– Prevention of damage caused by foreign objects or bodies.
– Reduction of unnecessary overloads.

Operational planning

– Real-time insight into the risk of blockages or stoppages.
– Improved traceability.

Frequently Asked Questions

  • How does the system ensure accurate readings in environments with high levels of dust and airborne particles?

    Pixelabs’ hardware is specifically designed for demanding industrial environments. The AI algorithms are trained to filter out environmental visual interference, ensuring that the processed data corresponds exclusively to the material on the conveyor belt.

  • What happens if the type of material supplied changes?

    When there are changes in rock type, the system detects the variation. Thanks to the included support service, our team can remotely recalibrate the models to maintain accuracy levels without the need for further on-site intervention.

  • Does the system require a plant shutdown for installation?

    No. The structure is designed to be non-intrusive and is installed “on top of” the existing conveyor belt. Mechanical assembly and wiring work are coordinated to take place during routine maintenance windows or scheduled shutdowns, with the work on the line taking less than 6 hours.

  • How does the Pixelabs signal integrate with our current control system (DCS/SCADA)?

    Integration is native and straightforward. The system transmits detections of foreign objects, out-of-specification stones, and volume via 4–20 mA current loops or standard protocols such as Modbus. This allows the plant system to receive the information just as it would from any other process sensor.

  • What is the estimated service life of the system and its maintenance requirements?

    The system is built with highly durable, industrial-grade components. Preventive maintenance is limited to cleaning the external protective covers of the equipment and optics, and replacing light bulbs if they burn out. On the software side, the system is updated via remote updates included in the support plan, ensuring that the technology never becomes obsolete, as well as through periodic recalibrations described in the product’s Technical Appendix.

Discover how AI-Material Scan can improve your business

Still have questions about the product? Schedule your demo with our experts
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(1)The data reflects how our client currently uses the system. Keep in mind that this information is shared based on mutual understanding. We’ve also estimated potential cost savings using details from our clients, keeping everything within the agreed terms and conditions. We recommend contacting us for detailed information. (2) This is a simplified explanation of the product’s functionality and may not fully represent the complete process involved. These representations are intended for the purpose of clarity and ease of understanding. We recommend contacting us for detailed information. (3) All images used in this website are for illustrative purposes only.

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