From the Lab to the Plant: How We Turn Computer Vision into Real Value

At Pixelabs, we have our own laboratory where our technical team works every day to turn ideas into real solutions. It is the space where we explore new approaches, develop AI models and build prototypes, all built on our Pixelabs AI-Engine, our scalable computer vision platform. This is also where visual AI solutions are validated, both for our own products and for each client’s custom projects. The laboratory includes a sample storage area, a workspace and a central zone that is currently running in demonstration mode with AI-Material Composition Analyzer. Our team is also working simultaneously on the ongoing development of AI models and the expansion of new features of the system interface.

Innovation that adapts to multiple sectors

The technology-driven approach developed in our laboratory has allowed us to build solutions capable of addressing a wide range of challenges. One example is AI-Material Composition Analyzer, our visual AI system designed to analyze, characterize and optimize industrial material flows in real time, through continuous inspection and automated image-based analysis of alternative fuels, waste, soil and raw materials.

Real-time analysis of alternative fuels

The use of alternative fuels is today one of the main challenges for cement plants. The properties of these materials — moisture content, particle size and calorific value — change constantly, and traditional methods, based on manual sampling or deferred analysis, cannot detect those changes in real time or support the fast decision-making that the process demands.

AI-Alt Fuel Cement addresses this problem with automated, continuous analysis that delivers immediate information on all these variables. This enables faster decisions on load acceptance or rejection, optimizes fuel usage and ensures compliance with current regulations. The system also detects materials that could cause emissions or blockages due to the accumulation of chlorine, sulfur or foreign objects.

Beyond cement: new solutions built on the same principle

Building on the development of AI-Alt Fuel Cement, we have created new solutions applying the same approach. One of them is AI-Biomass Analyzer, focused on real-time biomass analysis. The system measures critical variables such as moisture content, estimated net calorific value (NCV) and volumetric fuel flow, providing a better understanding of the material’s characteristics and enabling process adjustments that improve efficiency and simplify plant operations. It also triggers alerts when significant quality deviations occur and transmits data via standard process signals (4–20 mA), integrating seamlessly into existing DCS or SCADA systems and operating just like any other plant sensor.

At Pixelabs, every technological advance is a step towards a smarter, more efficient and more sustainable industry. We keep turning complexity into practical solutions that deliver real value at every stage of the process.