Centralizing 2,000+ Cameras Nationwide: Modernizing Video Surveillance for Industrial Facilities
Industrial Operations Demand Smarter Surveillance
Managing dispersed industrial facilities requires real-time visibility into contractor activities, equipment operations, and safety compliance. For organizations with nationwide footprints, legacy CCTV systems often create more problems than they solve.
When a leading industrial operator approached our integration partner, their existing setup exemplified these challenges:
- 2,000 cameras across regional industrial sites.
- Zero analytics: Manual review of footage for PPE violations, headcount tracking, and equipment monitoring.
- Costly expansions: Adding new sites required additional equipment for remote camera access , increasing expenses and deployment time.
The client needed a solution to consolidate disparate cameras into a single control panel with advanced video analytics—without overpaying for unnecessary features. They also wanted the flexibility to customize the interface gradually.
Together with our integration partner, we developed a unique system that seamlessly replaced the legacy surveillance vendor and laid the foundation for video analytics, accelerating the client’s workflows by 20%.
Challenge #1: Hassle-Free Video Surveillance
The client’s requirements:
- Centralize 2,000+ existing cameras into a unified system.
- Enable easy, cost-effective expansion to new facilities.
- Implement flexible access controls (different permission levels per location).
- Allow real-time system customization without delays.
The main challenge was the diversity of facilities. Internet connectivity ranged from fiber-optic to 3G. Off-the-shelf cloud solutions failed under weak connections, while local NVRs couldn’t provide centralized access.
Flussonic’s technologies were ideal for these conditions. Our systems reliably record archives even with unstable connections and deliver the best possible streaming quality.
Solution: A Hybrid System Powered by Flussonic Watcher
We offered the client two options:
- Use Watcher as a turnkey system (rejected—the client wanted a tailored interface).
- Build a custom portal using Flussonic Watcher as the backend via API (chosen solution).
The final architecture:
- Backend: Flussonic Watcher (streaming/recording engine).
- Frontend: Customized by the integration partner.
We deployed pre-configured Watcher servers for the integrator. These servers ingested camera streams, recorded archives, and enabled remote access for the client’s operators. Our deliverables:
- Hardware: Scalable servers (400 cameras each).
- Software:
- Flexible API for integration.
- DVR player with PTZ controls, embeddable in any interface.
We also provided end-to-end consulting—from camera setup to access management—while the integrator handled analytics.
Implementation Steps
- Defined user stories to prioritize core functionalities.
- Ran a pilot: Deployed a 400-camera test server to verify stability.
- Scaled gradually: Added servers as new facilities came online.
Customizations:
- Enhanced PTZ controls for intuitive camera operation.
- Developed an embeddable DVR player for live feeds.
- Simplified video sharing with regulators.
Challenge #2: Contractor and Safety Monitoring
Our partner already had a video analytics solution for industrial facilities. They used Watcher to ingest camera streams and metadata, then processed it in their own system. The client gained insights into:
- Worker headcounts.
- PPE compliance.
- Machinery types/quantities.
- Restricted area access (e.g., warehouses).
- Task progress and material usage.
With video evidence, the client could penalize contractors for missed deadlines or safety violations—previously possible only via manual monitoring by dozens of operators.
Results of the Collaboration with Mayak
✅ 2,000+ cameras centralized with HQ access.
✅ Stable streaming/recording regardless of network conditions.
✅ 20% faster workflows thanks to analytics.
✅ Reduced labor costs: Eliminated the need for manual monitoring.
Next Steps
- Scaling to 5,000 cameras.
- Adding client-requested features.
- Integrating new analytics modules.
- Refining permission systems.
Need to optimize processes at industrial facilities? Contact us—we’ll tailor the perfect solution.