Process monitoring plays a critical role in enhancing operational efficiency and safety in a wide range of industrial settings. Providing real-time visibility into production processes allows businesses to identify issues quickly, streamline operations, and maintain a safe working environment.

SCW is an industry leader in delivering end-to-end security solutions tailored to meet the unique needs of companies, agencies, and non-profits. Whether you require process monitoring systems or traditional security setups, we offer free consultations, flexible installation options, and world-class, US-based support. Our value-driven approach ensures that your security and operational goals are met seamlessly.

This helpful guide provides all the information you need on process monitoring. It explores its key benefits and challenges, the perfect system setup, and best practice process monitoring solutions in action.

What is Process Monitoring?

Process monitoring goes beyond traditional security concerns like vandalism and intrusion. It utilizes industrial process monitoring cameras to monitor and optimize various manufacturing processes, serving as the "eyes" of your operations. In manufacturing environments, process monitoring is a valuable addition that enhances efficiency and safety by allowing operators to oversee complex processes remotely, often using multiple cameras, reducing the need for employees to enter hazardous areas.

With these cameras in place, operators can monitor critical production areas, eliminating the need for physical presence in dangerous zones. This improves worker safety and reduces machine or line downtime, which can have a ripple effect on operations and delay orders.

Simply put, process monitoring enables continuous oversight, reduced downtime, and improved overall safety and productivity.

The Key Benefits of Process Monitoring

Implementing a process monitoring system offers several advantages, including:

• Real-Time Visibility: Continuous monitoring of industrial processes allows operators to spot potential issues early, preventing costly disruptions.
• Operational Control: With high-definition cameras and minimal latency, operators have unparalleled control over production lines, identifying problems and stopping processes before significant damage occurs.
• Incident Prevention: The right monitoring system reduces the chances of accidents, breakdowns, or malfunctions, improving workplace safety.
• Improved Compliance: Compliance standards are strictly enforced in industries such as manufacturing and processing. A monitoring system ensures that safety protocols are followed and quality standards are met.

One significant benefit of process monitoring systems is that they don’t require additional hardware like PCs. Once the cameras are set up, operators don’t have to deal with software logins, system updates, or complicated setups. The system simply provides a clear, uninterrupted feed of the production process, with latency measured in milliseconds for near real-time response.

Watch our recorded webinar to discover how process monitoring can enhance operational efficiency and safety. Learn about reducing latency, achieving high image quality in fast-paced environments, and implementing solutions for hazardous conditions. See real-world application and more

Examples of Effective Process Monitoring

Let's take a mulch processing facility as a real-world example of process monitoring in action. Mulch processing involves sending wood through a conveyor belt to a mulcher, but foreign objects like rocks or oversized wood pieces can severely damage equipment, causing interruptions and costly repairs.

To help solve this, cameras with high shutter speeds and zoom functionality can be installed along the production line, allowing operators to monitor the belt remotely from a safe location. If any foreign object is detected, they can immediately stop the process, preventing serious equipment damage.

Other use cases include monitoring critical machinery for early signs of wear and tear, identifying leaks, overheating, or other malfunctions before they lead to operational shutdowns. Cameras strategically placed around critical equipment offer an additional layer of security, ensuring that operations run smoothly and efficiently.

Process Monitoring Concerns & Solutions

While process monitoring offers significant advantages, it comes with its own challenges. Common concerns include:

• Latency: Any delay between the camera feed and operator view can impact decision-making. A direct camera-to-monitor connection minimizes this latency, ensuring quick responses.
• Environmental Conditions: Dust, humidity, and extreme temperatures can affect camera performance. Using cameras designed for industrial environments, such as those with high-speed shutters or durable casings, can overcome these challenges.
• Camera Placement: Proper placement is crucial for effective monitoring. Cameras must be positioned to cover critical areas without obstructing views or creating blind spots.

Did you know that High-speed shutter cameras are especially useful in environments where fast-moving equipment or materials are involved? These cameras capture high-quality footage, even in challenging conditions, ensuring that operators receive clear, actionable information.

Concern 1: Latency: A Major Concern in Process Monitoring

When it comes to process monitoring, latency—the delay between real-world events and the video feed—can be a critical issue. Even moderate latency can significantly reduce the window of time for operators to react, which is especially concerning in high-speed or sensitive industrial environments. Some systems can have seconds of latency, making real-time operation impossible. At SCW, we ensure our systems maintain latency in the low milliseconds range, providing near-instantaneous video feeds to support real-time decisions.

Causes of Latency:

1. Network (Local & Remote) – A slow or overloaded network can introduce delays, particularly in setups that rely on cloud services or involve multiple network layers.
2. Processing Software/Client – The software used to process the video feed can slow things down, especially if it isn’t optimized for low-latency applications.
3. Cloud-first systems – Systems that rely on the cloud for data transmission inherently introduce latency, as the video feed has to travel to a remote server and back.
4. Lesser camera equipment – Lower-quality cameras may take longer to capture, process, and transmit video, increasing latency.
5. More complicated cameras – Advanced cameras with multiple features can require extra processing time, which may introduce delays.

Solutions for Reducing Latency:

1. NVR Direct: Camera -> NVR -> Display

The simplest and most efficient way to reduce latency is by directly connecting your camera to the NVR (Network Video Recorder) and then to the display. This setup minimizes latency by reducing the number of steps involved.

• Use NVRs with plug-and-play networks to streamline setup and operation.
• HDMI output on the NVR ensures the quickest video transmission directly to the monitor.

Benefits of NVR Direct:

• There is no need for the video feed to traverse local or remote networks.
• Operates independently of network stability.
• No user input or PC required.
• The lowest latency possible, with delays measured in low milliseconds.

2. Decoders

Decoders are specialized hardware devices that allow multiple HDMI video outputs from the NVR. Each output can be customized to display different camera views, centrally managed via software. Decoders provide lower latency compared to software or PC-based viewing.

• No user interaction required—decoders are always on and display pre-configured views.
• Changes to camera views can be done via Viewstation or central software, without needing a PC for operation.

Benefits of Decoders:

• Consistent operation without needing user interaction.
• Simplifies the process of managing multiple camera views.
• HDMI inputs allow for easy distribution of video feeds to different monitors.

3. HDMI Extenders

While NVR Direct and decoders are great for reducing latency, physical distance between the NVR/decoder and the monitor can complicate setup, especially beyond 50 feet. HDMI extenders solve this problem by allowing you to run direct HDMI over Ethernet, maintaining low-latency video over longer distances.

• HDMI extenders can transmit up to 250 feet or more.
• They also support USB control if needed, allowing for flexible monitoring setups.
• HDMI extenders enable you to store the NVR/decoder in a secure location while keeping the monitor near the area of action.

By combining these solutions, SCW helps you build a robust, low-latency process monitoring system that supports real-time operations while minimizing delays and improving safety and efficiency.

Concern 2: Image Quality: A Critical Concern for Process Monitoring

When it comes to process monitoring, image quality plays a pivotal role in ensuring that operators can effectively oversee and manage industrial processes. However, this isn't just about having high resolution; it's about ensuring clarity in fast motion and providing actionable live footage that enables quick decision-making.

Motion Clarity

One of the key challenges in process monitoring is capturing fast-moving items with clarity. For this, both shutter speed and frames per second (FPS) are critical factors:

• FPS refers to how many images are captured in one second of video. Higher FPS allows smoother playback, but this alone doesn’t guarantee motion clarity.
• Shutter speed controls how clear moving objects appear. The faster the shutter speed, the sharper the motion, but this also limits the amount of light entering the camera.

Both factors need to be balanced to ensure motion clarity in environments with fast-moving items, such as conveyor belts or automated machinery.

Shutter Speed

The shutter speed of a camera directly impacts how clearly moving objects are captured. A faster shutter speed means better clarity for rapid movements, but it comes at the cost of reduced light entering the camera. This is why using low-light cameras in conjunction with adequate lighting is essential to ensure clear footage, even in darker environments. Keeping the camera lens clear of debris is also crucial, which can further degrade image quality.

Optical Zoom

Detail is another major aspect of effective process monitoring, particularly when it comes to live viewing. Optical zoom is far superior to digital zoom for capturing the necessary level of detail. Optical zoom allows cameras to focus on critical areas without sacrificing image quality, whereas digital zoom can lead to pixelation and loss of detail.

• Wide angles often result in wasted space, providing too broad a view without focusing on what matters most.
• Optical zoom allows operators to focus on specific areas, providing them with a clear, detailed view of crucial processes, whether it's monitoring machine performance or detecting potential issues in production lines.

Operator's Eyes

Beyond just improving detail, optical zoom also enhances the operator’s ability to concentrate on critical areas without unnecessary distractions. With optical zoom, operators can:

• Focus on important areas of production, minimizing distractions and optimizing monitoring efforts.
• Better organize their grid views by zooming in on essential processes, leading to more usable video.
• Some setups even allow for one camera to feed one monitor, giving operators full, detailed oversight of a single process in real-time.

Image quality for process monitoring goes beyond just resolution. It’s about ensuring motion clarity, using optical zoom for focused detail, and optimizing the overall view for operators to make real-time, actionable decisions.

At SCW, we ensure that our camera systems are equipped with the features necessary to deliver clear, actionable footage, even in the most demanding industrial environments.

Concern 3: Hazardous Environments: Debris, Heat, and Dangers in Process Monitoring

Process monitoring in hazardous environments introduces unique challenges, from dealing with debris to managing extreme heat and ensuring equipment can withstand dangerous conditions. These factors are critical to address, as they can affect both the efficacy of the monitoring systems and the safety of the personnel relying on them.

Debris

In industrial settings, especially in manufacturing, debris is a constant concern. Whether it’s dust, dirt, or particles generated by production processes, debris can obscure camera lenses and reduce visibility, making it difficult to monitor operations effectively. Over time, this accumulation can:

• Blur video feeds, making it hard to spot potential issues.
• Lead to wear and tear on camera components, reducing their lifespan.

To combat this, it’s important to use cameras with protective housings and self-cleaning mechanisms or ensure regular maintenance to keep lenses clear. Ruggedized cameras designed for harsh conditions can also help minimize the impact of debris.

Heat

Many process monitoring environments expose cameras to extreme heat, such as smelting plants, foundries, or any facility dealing with high-temperature operations. In such conditions, standard cameras may fail or experience performance issues, such as overheating or distortion in the video feed.

Heat-resistant cameras, specifically designed to operate in high-temperature environments, are essential. These cameras can function in extreme heat without compromising image quality or durability. Some setups also incorporate cooling systems or protective housing to shield sensitive camera components from intense temperatures.

Dangerous Conditions

In environments with chemical exposure, explosive gases, or other hazards, cameras must be designed to withstand potentially volatile conditions. Standard surveillance equipment would not suffice in these areas, where ruggedness and reliability are crucial for both monitoring and preventing incidents.

It's critical to deploy explosion-proof cameras or systems built to meet specific safety standards (like ATEX or IECEx certifications) for these environments. These cameras ensure continuous monitoring without posing additional risks in hazardous conditions, where even a small spark could trigger a dangerous situation.

Solutions for Hazardous Environments

In industrial environments, where debris, extreme heat, and other hazards are common, ensuring that your process monitoring cameras function properly is crucial for safety and operational efficiency. Here are some effective solutions to help mitigate these challenges:

Zoom, Zoom, Zoom

When possible, position cameras outside the main debris areas to reduce exposure to harmful elements. Using zoom cameras, like the Archer 2.0 v2, allows you to monitor critical areas from a distance without placing the camera directly in harm's way. This approach reduces the camera’s contact with debris, heat, and other environmental hazards, prolonging the equipment's lifespan.

Cleaning for Clear Vision

Even cameras positioned at a distance will accumulate debris over time. Regular cleaning is essential to maintain a clear image and ensure accurate monitoring. Use compressed air to blow away any loose particles before wiping the camera, as debris can scratch the lens. For stubborn dirt or metal swarf, spraying the lens with water before cleaning helps to remove contaminants safely.

Temperature Ratings and IP Protection

Temperature fluctuations can be a significant challenge in hazardous environments. Every camera has a temperature rating, so it’s essential to choose equipment suited for extreme conditions. For example, the Archer 2.0 v2 can operate in temperatures ranging from -40°F to 140°F, making it ideal for both freezing and high-heat environments.

When placing cameras in areas with rising heat, it's crucial to pay attention to heat sources and ensure cameras are positioned away from direct exposure. Additionally, using cameras with a high IP rating ensures they are well-protected against dust, debris, and moisture, further extending their longevity.

Software for Process Monitoring: SCW Viewstation PC/Mac Viewing Software

For powerful process monitoring you can rely on, SCW offers the innovative Viewstation PC/Mac viewing software. While this software is ideal for central management and monitoring across multiple sites or Network Video Recorders (NVRs), it’s not the first choice for direct process monitoring due to potential latency issues.

Here are the key points to consider:

• Latency: Although the software is reliable, there will always be some latency, even if measured in milliseconds.
• User Input: Operators must log in and interact with the software, which may require training and ongoing management, making it less ideal for direct process oversight.
• Centralized Control: Viewstation is best suited for managers overseeing multiple facilities or areas. It offers a comprehensive view of operations across locations, though it’s less practical for operators monitoring live, high-speed processes.

For direct process monitoring, SCW recommends a more streamlined approach with direct or decoder connections, which offer lower latency and require minimal operator interaction.

The Recommended Camera for Process Monitoring: Archer 2.0 v2

When it comes to the perfect industrial process monitoring camera, you can't go past the Archer 2.0 v2.

The Archer 2.0 v2 is a cutting-edge bullet camera designed to meet the demanding needs of industrial and commercial environments. Featuring 2MP resolution, low-light performance, 60FPS capability, and a 10x optical zoom, this camera excels in monitoring fast-paced and low-visibility areas. It's a top choice for applications requiring precise inspection, comprehensive data acquisition, and advanced features like thermal imaging.

Low-Light Performance

One of the standout features of the Archer 2.0 v2 is its low-light performance. In industries where operations continue 24/7, and lighting can be inconsistent, this camera’s ability to capture clear footage in dim conditions is invaluable. Equipped with advanced sensors, the Archer 2.0 v2 ensures that even in low-light or nighttime scenarios, you receive high-quality, detailed images, reducing the risk of missed events or misinterpreted data.

60FPS for Fast-Paced Monitoring

In fast-moving environments, such as manufacturing plants or processing facilities, clarity during motion is critical. The 60 frames per second (FPS) capability of the Archer 2.0 v2 ensures that every movement is captured with precision, preventing any blur or distortion that might occur with lower frame rates. Whether it’s monitoring machinery in real-time or keeping an eye on rapid production lines, the high FPS provides smooth, actionable footage that can be used for both live monitoring and post-event analysis.

10x Optical Zoom for Detailed Surveillance

The 10x optical zoom feature allows operators to zoom in on specific areas without sacrificing image quality, making it ideal for long-range surveillance or detailed inspections of critical zones. Unlike digital zoom, which can pixelate and degrade the image, the optical zoom maintains full resolution and clarity. This is especially useful for monitoring small, intricate details in complex industrial environments, such as conveyor belts, machinery parts, or distant perimeter zones.

Addressing Specific Monitoring Needs

• Low-light performance ensures visibility in dim or nighttime conditions, making it ideal for facilities where lighting may be limited or expensive to maintain.
• 60FPS capability is perfect for fast-paced operations where capturing smooth, blur-free footage is essential, such as on production lines or areas with fast-moving vehicles or machinery.
• The 10x optical zoom enables clear, detailed monitoring over long distances, allowing operators to focus on specific areas without physically moving the camera or losing image quality.
• The Archer 2.0 v2 supports coax cable connections, ensuring reliable transmission of high-quality video signals over long distances. This is particularly beneficial in large-scale installations where maintaining signal integrity is essential for accurate data acquisition and real-time monitoring.

Whether you're overseeing production lines, monitoring critical equipment, or securing large industrial perimeters, the Archer 2.0 v2 offers the precision, speed, and clarity required to ensure continuous, reliable oversight.

How SCW Are Experts in Process Monitoring

At SCW, we understand that process monitoring can present unique challenges, and we offer tailored solutions to address them. We provide free consultations to help you navigate these challenges and select the best process monitoring system for your facility. Whether it’s reducing latency, selecting the right cameras, or choosing the best installation method, our team of experts is here to guide you through every step of the process.

As trusted experts in all aspects of process monitoring, we pride ourselves on delivering solutions that meet the specific needs of each industry. Our direct connections and decoder solutions are particularly effective for low-latency, high-speed environments.

An SCW Success Story

Lumber Mill

The team at SCW recently delivered a comprehensive and connected process monitoring system for a lumber mill that processes over 200 million feet of lumber annually. This facility relies heavily on its debarking and saw line operations, both of which are controlled remotely through camera feeds. With the cab operators positioned at the start of a 400-foot line, real-time, high-quality video is essential. There are no humans physically present along the production line, making it critical that the operators have clear, near-zero latency video feeds to monitor the entire process.

To meet these needs, SCW designed a solution where the Network Video Recorder (NVR) was housed directly in the operator's cab, utilizing both HDMI and VGA outputs to connect to two screens. This setup allowed the operator to monitor multiple camera views simultaneously—four on each screen. The system was configured with a mix of cameras: some equipped with zoom lenses, like the Archer model, for areas that required precise focus, and others with fixed lenses for broader coverage. By strategically positioning the cameras along the production line, we ensured that fast-moving areas had the necessary shutter speed to capture every detail, while slower zones used more standard cameras, balancing quality and cost.

In addition to supporting the cab operators, the system also fed into the mill’s control tower, where managers oversee machinery and production data. They can easily pull up any camera feed via SCW's ViewStation software. This allows the control room team to quickly assess any issues, such as fluctuations in production data or potential mechanical problems. The control room, located further away from the lines, benefits from this remote monitoring capability, which enables them to keep an eye on multiple lines without being physically near the production areas.

The cameras have become an essential part of this lumber mill's operations. SCW worked closely with the mill's team to ensure that the system was tailored to their specific operational needs, as well as their budget. Beyond process monitoring, the system is integrated into their overall security setup, allowing for intrusion detection and safety monitoring. The universal software can be accessed from computers and smartphones, giving the team full flexibility to monitor operations from anywhere.

This robust system now provides the mill with the reliable, high-quality monitoring they need to ensure efficient, safe, and uninterrupted production.

Helping Your Operations Run Smoothly

SCW is more than just a security camera company. We are your partners in efficiency and safety, offering customized solutions that enhance your operations.

Whether it’s process monitoring or traditional security, SCW is here to help you protect your assets and streamline your processes.

For end-to-end security solutions that benefit every aspect of your company, you can't go past the trusted team at SCW.

Contact us today for a free consultation and see how we can support your business with smart, innovative solutions for your biggest challenges.