Achieved a 70% reduction in temperature-related failures with AI-powered monitoring of switchyard assets, ensuring early detection of thermal anomalies and potential equipment faults for enhanced reliability and predictive maintenance.
Achieved 70% Reduction in downtime of conveyor failures with Ripik AI conveyor belt monitoring system. This ensured smoother operations, minimized downtime, and delivered significant cost savings.
Achieved an 82% reduction in crusher blockages and a 20% decrease in unwanted stoppages in cement crusher operations by detecting oversized rocks in real time. This led to smoother operations, reduced downtime, and substantial cost savings.
In the world of cost-competitive steel market, our client managed to improve fuel rate and throughput by real time Nut Coke tracking, resulting in sustainable steel production.
Real-time camera intelligence to monitor materials, equipment, and processes, driving efficiency and consistency in industrial operations.
Hosts and manages hundreds of Vision AI Agents, enabling you to customize, deploy, and scale real-time monitoring solutions instantly across operations.
Let us walk you through a tailored demo experience.
Achieved a 70% reduction in temperature-related failures with AI-powered monitoring of switchyard assets, ensuring early detection of thermal anomalies and potential equipment faults for enhanced reliability and predictive maintenance.
Achieved 70% Reduction in downtime of conveyor failures with Ripik AI conveyor belt monitoring system. This ensured smoother operations, minimized downtime, and delivered significant cost savings.
Achieved an 82% reduction in crusher blockages and a 20% decrease in unwanted stoppages in cement crusher operations by detecting oversized rocks in real time. This led to smoother operations, reduced downtime, and substantial cost savings.
In the world of cost-competitive steel market, our client managed to improve fuel rate and throughput by real time Nut Coke tracking, resulting in sustainable steel production.
Real-time camera intelligence to monitor materials, equipment, and processes, driving efficiency and consistency in industrial operations.
Hosts and manages hundreds of Vision AI Agents, enabling you to customize, deploy, and scale real-time monitoring solutions instantly across operations.
Let us walk you through a tailored demo experience.
Achieved 95% accuracy in hotspot detection with Ripik’s real-time hotspot monitoring system, enabling early identification of thermal anomalies and driving a 25–50% increase in refractory life.
A leading steel manufacturer faced frequent refractory wear and unplanned furnace shutdowns, resulting in high maintenance costs and reduced productivity. Despite routine thermal checks, minor anomalies and localized hotspots often went unnoticed—shortening furnace lifespan and disrupting operations.
Undetected hotspots across the furnace shell led to gradual refractory damage, unexpected temperature spikes, and sudden equipment failures. Limited thermal visibility caused early warning signs to go unnoticed, leading to costly downtime and safety risks.
Undetected refractory wear gradually weakened furnace integrity, causing uneven heating, rising shell temperatures, and unexpected equipment failures. Small cracks and erosion progressed unnoticed, leading to reliability issues & reduced refractory life.
Critical issues such as rising shell temperatures, refractory thinning, and localized damage were often missed due to limited visibility. These overlooked signs escalated into major faults, causing unexpected failures and reducing overall furnace reliability.
Frequent refractory replacement became necessary as wear, hotspots, and unnoticed damage accelerated deterioration. The lack of early detection increased thermal stress on the lining, shortening its lifespan and driving up maintenance cost and downtime.
Effective furnace monitoring helped extend refractory life by maintaining stable temperatures and preventing overheating or thermal shocks. With automated alerts and timely interventions, wear and erosion were minimized. This resulted in a longer refractory lifespan, lower maintenance costs, and improved furnace reliability.
10M$
Expected annual value generation
The AI-powered furnace monitoring system enabled early detection of wear and hotspots, reducing unplanned shutdowns and optimizing maintenance activities—resulting in an expected annual value generation of over $1 million through improved reliability and extended refractory life.
25-50%
Increase in refractory life
Real-time hotspot monitoring, combined with continuous tracking of shell temperature and wear patterns, enabled timely maintenance and precise interventions—resulting in a 25–50% increase in refractory life and improved furnace reliability.
95%
Accuracy in hotspot detection
The AI-driven hotspot monitoring system achieved 95% accuracy in detecting critical temperature anomalies, ensuring precise identification of localized heating and enabling rapid intervention to prevent refractory damage and equipment failures.
See how leading companies across steel, cement, oil & gas, energy, automotive, chemicals, pharmaceuticals, FMCG, and other industries are transforming their operations with Ripik AI’s Vision AI solutions—driving real-time insights, enhanced safety, and intelligent process optimizations across the industrial landscape
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