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Real-Time Cement Bag Counter for Industrial Conveyor Systems
AI-powered vision system that counts cement bags on conveyor belts in real-time using YOLO-based object detection, virtual lines, and tracking.
Project Overview
CemTrack AI is a real-time computer vision solution for monitoring and counting cement bags on conveyor belts. Using YOLO detection models and virtual line-crossing logic, the system identifies each bag, tracks its movement, and increments the count when it crosses a predefined line. Designed for industrial environments, it ensures accurate inventory tracking and operational transparency with minimal human intervention.
Key Features
Real-Time Object Detection & Tracking
- 🎥 Detects and tracks each cement bag on the conveyor belt in real time.
Persistent Bag ID Tracking
- 🔁 Assigns unique IDs to bags to prevent double-counting.
Virtual Line Counting Logic
- 📏 Counts bags precisely when they cross a predefined virtual line.
On-Screen Visualization
- 🧾 Displays labeled IDs, detection boxes, total count, and timestamps.
Video Logging (Optional)
- 💾 Save annotated video footage for audits or documentation purposes.
Technology Stack
- 🐍 Programming Language: Python
- 🧠 Object Detection & Tracking: YOLO
- 🎥 Computer Vision: OpenCV
Use Cases
- 🏭 Cement manufacturing and packaging plants – automate bag counting.
- 📦 Real-time inventory logging for bulk packaging systems.
- 🔧 Conveyor belt monitoring in mining, grain, or fertilizer industries.
- 📝 Audit compliance in large-scale industrial units.
Custom Enhancements
- 📊 Export count logs to CSV or industrial database systems (SAP, ERP).
- 🔔 Real-time alert system for conveyor errors or missed bags.
- 🌐 Remote monitoring dashboard integration.
- 🧠 Defect detection (torn, misaligned bags).
- 📱 Edge deployment on Jetson Nano or Raspberry Pi.
Conclusion
CemTrack AI enhances operational efficiency in cement plants by automating labor-intensive bag counting. With YOLO-based detection, visual tracking, and scalable architecture, it integrates seamlessly into existing camera setups for smarter industrial monitoring and inventory management.