Empty Crate Counting System
AI-Powered Crate Inventory Tracking via High-Speed Computer Vision
About the Solution
Empty Crate Counting System is an automated computer vision system that accurately counts empty dairy crates using CCTV cameras and AI algorithms.
The solution eliminates manual counting errors and provides real-time crate inventory visibility — reducing losses and improving operational efficiency across dairy facilities.
The Challenge
Dairy processing plants handle tens of thousands of reusable plastic crates daily as empty crates return from distribution routes to washing and filling lines.
Manual human tallying on fast-moving conveyors and loading docks resulted in frequent miscounts, high shrinkage/theft, disputed distributor balances, and costly conveyor bottlenecks.
Our Technical Solution
Ivon Tech Hub deployed an edge-based computer vision solution utilizing existing or standard industrial CCTV cameras placed over return conveyors and dock bays.
Trained deep learning object tracking models (YOLO + DeepSORT) capable of differentiating crate types, stacked configurations, dirty crates, and bidirectional conveyor motion.
Integrated real-time telemetry streaming counts directly into plant ERP databases with automated anomaly alerts.
Key Benefits
- Automated crate counting
- Real-time inventory updates
- Camera-based monitoring
- Reduced manual intervention
- Loss prevention
- Historical analytics
Business Impact
- Accurate crate tracking
- Reduced crate losses
- Lower labor costs
- Increased operational efficiency
Experience Empty Crate Counting System
Explore live public apps, stores, and demo walkthroughs delivered for this client.
Platform Capabilities
High-Speed Conveyor Detection
Real-time counting at conveyor speeds exceeding 120 crates per minute with 99.4%+ accuracy.
Stack & Layer Disambiguation
Advanced vision algorithms accurately enumerate vertical stacks of nested or collapsed crates.
Bidirectional Directional Filtering
Distinguishes between inward incoming returns, conveyor reversals, and outward dispatch flows.
Real-Time ERP Sync
Instant synchronization with SAP, Oracle, and custom plant ERPs via lightweight REST and MQTT protocols.
Shrinkage & Loss Analytics
Reconciles dispatched crates against returned crates per delivery vehicle to immediately pinpoint shortages.
Automated Shift Reports
Generates shift-wise and route-wise summary reports with video clip snapshots for contested counts.
Technologies & Frameworks
Built using industry-standard modern engineering tools for high scalability, real-time response, and enterprise security.
Ready to Accelerate Your Digital Journey?
"Your partner in innovation, helping businesses build high-performance software, mobile apps, and AI solutions."