Looking for IP camera and NVR system to monitor beverage packaging

P

PackageSurveillance

n3wb
Jul 7, 2023
10
8
OR
Good morning! This is my first post, introduction, and a brief summary of what I am looking for - hopefully someone can help.

I work in a beverage packaging facility which takes great care to prevent the inclusion of glass fragments in our finished products. We have 4 lines that are filling beverages into glass bottles and we have a fairly rigorous program to monitor the equipment for errant glass fragments, and as part of this program we are looking to add some surveillance cameras inside our filling/capping equipment so that we can better diagnose the causes of bottle breakage and assess the level of hazard for finished goods that may be adjacent to the breakage incidents. I'm hoping someone can point me towards a system that would work best for us. To be clear, however, we are not needing to be able to see broken glass fragments and where they land during equipment operation - that level of detail is not needed. We only need to see where and when an event occurred with as high of a level of confidence as possible. While I am trying to educate myself on this to make the best decision we can, I don't really have time to become a specialist on this material. Here are the details and requirements, to the best of my current understanding:

  • General
    • Budget ~$10-20K
    • Installation can be done by in-house Maintenance and IT teams.
  • Cameras
    • Need roughly 8 cameras, powered over Cat-5/6
    • Motion detection and night vision are not a priority. "Weather" resistance is a priority.
    • Need a good frame rate and resolution (watching a packaging rate of up to 250 bottles per minute)
    • Must be able to focus to objects within the 2-15' range, but any given camera will be at a fixed, static focal length
  • Storage
    • No cloud storage or professional monitoring is desired
    • NVR with enough storage for ~48hrs of footage for all camera feeds
    • Remote access to current and stored footage is a plus
    • Ability to export footage in a common file format is desired
Thank you so much for your attention and assistance, and please let me know if I am missing any details that are needed for informed decision-making.

-PS
 
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This camera: Review-OEM Loryta IPC-T5442T-ZE Varifocal 4mp camera (Dahua) | IP Cam Talk
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Use a dedicated PC with the software Blue Iris installed, Blue Iris - Video Security Software
Blue Iris will run well on a refurbished business class PC, such as: this PC
Blue Iris is much easier to review recordings on than any NVR is.

Put Blue Iris, the operating system, and the BI database on the SSD.
Install a Western Digital Purple surveillance drive to put the recordings on.
 
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And you'll need a good POE switch ==>> NETGEAR 8-Port Gigabit Ethernet Unmanaged PoE Switch (GS108LP) - with 8 x PoE+ @ 60W Upgradeable, Desktop, Wall Mount or Rackmount, and Limited Lifetime Protection

NOTE: The above switch is not industrial-rated and should be located in the same environment as the server PC and monitor with controlled ambient temp, etc.

Cameras should be mounted on the manufacturer's matching junction boxes so the camera pigtail (connections) will be protected and those connections, even inside the box, should be environment-proofed as here because of high humidity and vibration.

EDIT 7/7 @ 1158 CT:
The Server PC and the POE switch should be powered by a UPS (Battery Backup) for additional protection and dependability, minimum size ==>> APC UPS 1000VA UPS Battery Backup and Surge Protector, BX1000M Backup Battery Power Supply, AVR, Dataline Protection
 
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PackageSurveillance said:
Based on the thread you quoted for that camera, the closest focus distance is not quite 4'. There are a few situations in our equipment where that wouldn't be close enough for us to view what needs to be viewed. Do you know if there are other options that can focus closer than 1.2m?

Thanks,
-PS
Click to expand...
How close do you need?
 
I know you mentioned your use case, but these cameras may or may not be able to accomplish what you want. I would suggest buy one camera and test it by itself with an SD card before you invest in a full system being mentioned.

Surveillance cameras are not designed for that type of capture that you are looking for. Most will cap out at 30FPS but may be glitchy and problematic running at that speed.

They would make okay cameras for general overview type things, but depending on the size of the product and type of failure, that could prove problematic.

These types of cameras are not GoPro or Hollywood type cameras that offer slow-mo capabilities and other features. They "offer" 30FPS and 60FPS to appease the general public that thinks that is what they need, but you will not find many of us here running more than 15 FPS; and movies are shot at 24 FPS, so anything above that is a waste of storage space for what these cameras are used for. If 24 FPS works for the big screen, I think 15 FPS is more than enough for phones and tablets and most monitors LOL. Many of my cameras are running at 12FPS.

If your unique case requires a higher FPS, you will find surveillance cameras are not going to meet your needs and you need to get a camera capable of that - and spend some serious money if a gopro isn't sufficient.

We have had recently people come here after purchasing cameras in two instances where they were wanting 60FPS - one was a tennis club and another was a youth soccer club. In both cases they found that these types of cameras were not capable of what they were wanting to do. Sure the cameras could run faster FPS, but it still didn't provide them with the level of detail they were looking for. I recall the soccer club had a decent quality PTZ ($800) that is fine for a residential or retail/commercial installation to capture a thief, but to cover the action of the soccer field it wasn't capable of meeting their needs. And because of the extremely fast motion, it was creating a halo type effect around the action (which can be seen in certain lighting conditions). These cameras are good, but not good enough to catch the rotation of a ball for example.

Another came here trying to use this cameras for a race track in the pit stalls to monitor lug nuts and violations and it just couldn't do it.
 
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wittaj said:
I know you mentioned your use case, but these cameras may or may not be able to accomplish what you want. I would suggest buy one camera and test it by itself with an SD card before you invest in a full system being mentioned.

Surveillance cameras are not designed for that type of capture that you are looking for. Most will cap out at 30FPS but may be glitchy and problematic running at that speed.
...
Click to expand...

That's kind of what I was afraid of. Fortunately, we don't need the higher speeds for all the cameras in the system, so we may be able to split up the duties across a couple different camera types. Thanks for the insight.
 
I think if you adjust the shutter speed higher, you dont have to start out at 30 FPS,,,,try a 15 FPS with a 1/1000 Shutter or a 1/2000 shutter with lots of light.
 
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