There are few environments as challenging for video monitoring as sawmills. In a sawmill, precision must meet productivity, and a video monitoring system needs to support both. However, amongst the vibration of heavy machinery and the inherent challenges of rugged environments, implementing a video monitoring system is no small task. Sawmills present unique challenges, from extreme working conditions and dust-filled air to inaccessible areas and dynamic production processes. So, how do you create a video monitoring system that supports seamless productivity in sawmills? Opticom’s 50+ years of experience in sawmilling says “yes.” Which is why the Opticom Industrial Camera systems are the preferred provider of video monitoring solutions for sawmills throughout North America, and now being introduced to the Australian and NZ markets. At Gibson’s we work with sawmill managers nearly every day, so we understand their challenges inside and out. Here are some common issues you might encounter when building a video monitoring system for sawmills, along with how to tackle those challenges.
The Challenges of Sawmill Video Monitoring
In sawmills, video monitoring must adapt to the environment, not the other way around. You want products designed to withstand tough conditions—and so do we. Equally important, our video monitoring products make monitoring straightforward, not just another tough task.
1. Mounting Cameras on Heavy, High-Vibration Machinery
Sawmill equipment experiences high levels of vibration and noise which can severely damage ordinary video cameras. Before working with Opticom, many sawmill managers resorted to makeshift solutions, like mounting cameras on rafters, or found themselves replacing cameras every few weeks! Mounting cameras in rafters or other suboptimal locations is not only cumbersome but also compromises the quality of your video feed. When you’re restricted in where you can place the cameras due to their fragility, they can’t capture the angles or quality you need. Opticom’s rugged industrial cameras, such as the CC02 and CC04, are specifically designed to withstand high levels of vibration, even from heavy machinery found in sawmills. You can mount Opticom cameras directly on your sawmill equipment—like log debarkers or chippers—to get all the angles and views you require. Using a vibration mount allows for flexible placement while providing extra protection from the hazards of sawmills.
2. Frequent Replacement of Commercial Cameras
While ordinary off-the-shelf cameras may seem inexpensive, they often break down quickly in a sawmill environment. Given the dust, debris, and vibrations, some cameras may last less than a week. (We’ve had clients who, before Opticom, were replacing cameras almost weekly.) If you go for ordinary off-the-shelf cameras, you’ll end up paying significantly more for replacements every week or month. You need to factor in both the cost of the cameras and the labour involved in replacing them, as well as downtime while the cameras are offline. Opticom cameras are ruggedised and specifically designed for the harsh industrial conditions in a sawmill. They last for years, not months, significantly lowering your total cost of ownership from the outset.
3. Cameras Getting Hit by Logs
Sawmills aren’t for the faint-hearted. Debris, logs, and boards move quickly around the mill. When cameras are placed correctly, they are right in the thick of the action, which means there’s always a risk of them being struck by debris or even a log. In fact, it has happened—more than once. When we say Opticom cameras can withstand almost anything, we mean it literally. One of Opticom’s clients sent a video showing what happens to a camera when it gets hit by a log, yet the camera remained in perfect working condition; the only part that needed replacing was the vibration mount. That’s not the only instance. Opticom has run trials involving driving over cameras with a truck, and one was even speared by a board, yet again, the camera continued to work, needing only the vibration mount replaced. Things happen in sawmills. This is why you need rugged, industrial Opticom cameras that can handle whatever is thrown at them—literally.
4. Remote Video Monitoring in Sawmills
Around heavy machinery, accidents and incidents are common. You want to minimise these risks; the last thing you need is to add more people near the high risk machinery. That’s why sawmills need a robust remote video monitoring solution. With Opticom technology, all you need is a video monitorat a safe distance from logs and debris. An Operator can monitor activities inside the mill on their networked video feeds and intervene if they spot a potentially faulty piece of machinery or a potential incident. Operators and managers can also view video feeds on a mobile app to see operations in real time. Simply download the app, connect it with your mill’s video feeds, and securely monitor operations on the go.
5. Difficulties in Obtaining Close Views of Operations
While monitoring loading operations and other tasks outside the “heart” of a sawmill is relatively straightforward, getting close-up views of the line is trickier—unless you have Opticom cameras. As previously mentioned, off-the-shelf cameras can’t be mounted on or near equipment. Sawmill managers do what they can to get views of the line—mounting cameras in rafters, positioning far away and zooming in with low-quality output, and more—but they don’t have to. Opticom cameras can be mounted in the harshest, most rugged spaces. This way, you can:
– Detect potential machinery issues as early as possible
– Avoid accidents and various incidents
– Prevent costly downtime
– Keep workers safe
You get a full, real-time view of your sawmill equipment, allowing you to operate it safely and efficiently.
Choosing the Right Sawmill Video Monitoring System
While these are some of the most common challenges we’ve seen with sawmill video monitoring, we understand that every sawmill is unique and has its own specific needs. This is why Gibsons representatives work to understand the requirements of your sawmill and recommend solutions tailored to your mill.
To learn more about quality industrial security cameras, contact us on 02 6559 4001 or email us at info@aegibsonman.com.au