AI Automation for
AI Automation for
AI Automation for
Steel & Metal Industry
Steel & Metal Industry
Steel & Metal Industry
Integrated automation, AI-powered monitoring, and compliance infrastructure for steel and metal operations deployed on your existing plant network.
30–50%
Reduction in unplanned downtime
24/7
Real-time belt & equipment monitoring
ISO 45001
Safety compliance infrastructure
Trusted by Leading Enterprises Globally
Trusted by Leading Enterprises Globally
Industry Hazards
Most Common Challenges in
Steel & Metal Industry
Each one has a measurable impact in downtime, safety, energy costs, or compliance readiness. Without continuous monitoring, they persist across shifts.
Unplanned Conveyor Failures
Unplanned Conveyor Failures
Unplanned Conveyor Failures
Safety Gear Non-Compliance
Safety Gear Non-Compliance
Safety Gear Non-Compliance
Fire & Uncontrolled Heat Events
Fire & Uncontrolled Heat Events
Fire & Uncontrolled Heat Events
Height & Crane Incidents
Height & Crane Incidents
Height & Crane Incidents
Limited Real-Time Plant Visibility
Limited Real-Time Plant Visibility
Limited Real-Time Plant Visibility
Compliance Gaps During Audits
Compliance Gaps During Audits
Compliance Gaps During Audits
Unauthorized Zone Access
Unauthorized Zone Access
Unauthorized Zone Access
Energy Overconsumption
Energy Overconsumption
Energy Overconsumption
Our Solutions
Scalable Capabilities for
Every Challenge
Integrates directly with your existing PLCs, SCADA, and DCS over Modbus, Profinet, and OPC-UA. No new hardware required on the plant floor.
Safety Monitoring
AI-powered monitoring that detects safety violations, hazards, and non-compliance across your plant floor continuously, across every shift.
Security & Access Control
Automated surveillance and access management systems that protect restricted zones, track all vehicles, and maintain a complete entry and exit record.
Operations Intelligence
Real-time operational monitoring that tracks vehicle movement, worker productivity, material handling, and energy consumption across the plant.
01
Safety
Safety Helmet & Vest Detection
AI monitoring continuously flags any worker entering designated zones without the required helmet or high-visibility vest. Alerts sent instantly with location, timestamp, and visual evidence.
02
Safety
Safety Harness Detection
For work at height — platforms, open edges, maintenance — the system checks whether a harness is properly worn and intervenes before an incident, not after.
03
Safety
Fire & Smoke Detection
Detects fire or smoke at its earliest visible stage. Integrated with plant hooters, SAP, and alert systems for automated incident logging — effective where traditional detectors fall short.
04
Safety
Person Under Suspended Load
One of the most common causes of fatal accidents in steel plants. Real-time alerts give crane operators and safety teams the seconds they need to stop operations and clear the area.
05
Safety
Coil Lashing Safety Detection
Improper lashing during steel coil handling creates the risk of coils shifting or falling. Flags non-compliant lashing against daily handling standards specific to steel operations.
06
Safety
Crowd & Occupancy Monitoring
Tracks occupancy in restricted areas, confined spaces, and zones near heavy machinery. Alerts when the safe limit is exceeded to prevent overcrowding in high-risk areas.
07
Safety
Object Detection in Pathways
Materials, tools, or equipment left in walkways and access routes create collision and tripping hazards. Identifies objects so teams can clear the area promptly.
08
Safety
Safety Shoes & Gloves Detection
Monitors compliance for foot and hand protection in zones where contact with metal, heat, or chemicals is a daily risk. Violations flagged in real time without manual supervision.
Safety Monitoring
AI-powered monitoring that detects safety violations, hazards, and non-compliance across your plant floor continuously, across every shift.
Security & Access Control
Automated surveillance and access management systems that protect restricted zones, track all vehicles, and maintain a complete entry and exit record.
Operations Intelligence
Real-time operational monitoring that tracks vehicle movement, worker productivity, material handling, and energy consumption across the plant.
01
Safety
Safety Helmet & Vest Detection
AI monitoring continuously flags any worker entering designated zones without the required helmet or high-visibility vest. Alerts sent instantly with location, timestamp, and visual evidence.
02
Safety
Safety Harness Detection
For work at height — platforms, open edges, maintenance — the system checks whether a harness is properly worn and intervenes before an incident, not after.
03
Safety
Fire & Smoke Detection
Detects fire or smoke at its earliest visible stage. Integrated with plant hooters, SAP, and alert systems for automated incident logging — effective where traditional detectors fall short.
04
Safety
Person Under Suspended Load
One of the most common causes of fatal accidents in steel plants. Real-time alerts give crane operators and safety teams the seconds they need to stop operations and clear the area.
05
Safety
Coil Lashing Safety Detection
Improper lashing during steel coil handling creates the risk of coils shifting or falling. Flags non-compliant lashing against daily handling standards specific to steel operations.
06
Safety
Crowd & Occupancy Monitoring
Tracks occupancy in restricted areas, confined spaces, and zones near heavy machinery. Alerts when the safe limit is exceeded to prevent overcrowding in high-risk areas.
07
Safety
Object Detection in Pathways
Materials, tools, or equipment left in walkways and access routes create collision and tripping hazards. Identifies objects so teams can clear the area promptly.
08
Safety
Safety Shoes & Gloves Detection
Monitors compliance for foot and hand protection in zones where contact with metal, heat, or chemicals is a daily risk. Violations flagged in real time without manual supervision.
Safety Monitoring
AI-powered monitoring that detects safety violations, hazards, and non-compliance across your plant floor continuously, across every shift.
Security & Access Control
Automated surveillance and access management systems that protect restricted zones, track all vehicles, and maintain a complete entry and exit record.
Operations Intelligence
Real-time operational monitoring that tracks vehicle movement, worker productivity, material handling, and energy consumption across the plant.
01
Operations
Vehicle Turnaround Time Tracking
Tracks every vehicle from entry to exit, linked to its number plate. Identifies bottlenecks at weigh bridges and bays and creates an auditable movement log.
02
Operations
Worker Productivity Analysis
Monitors workstation occupancy and activity across shifts. Tracks active, idle, and unoccupied stations to improve shift planning and workforce allocation.
03
Operations
Tarpaulin Detection
Checks outgoing vehicles for tarpaulin covers before gate exit. Flags non-compliant loads to prevent material spillage and meet transport regulations.
04
Operations
Bucket Overfill Detection
Detects when excavator buckets or material containers exceed safe capacity. Alerts the operator before an overloaded bucket is moved, preventing spillage and equipment strain.
05
Operations
Material Detection on Conveyors
Identifies foreign objects, spillage, and material irregularities on moving conveyor belts. Prevents belt damage and unplanned stoppages from undetected material issues.
06
Operations
Energy Monitoring Dashboard
Per-machine energy tracking connected to your existing plant network. Flags overconsumption against benchmarks and provides the data needed for ISO 50001 reporting.
Our Capabilities
Our Capabilities
Complete Operational Technology Stack for
Steel & Metal Industry
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
Industrial Automation
PLC and SCADA integration with existing plant systems
MES and ERP connectivity (SAP, Oracle, Microsoft Dynamics)
Industrial IoT sensor networks for temperature, vibration, pressure, and load
Communication protocols - OPC-UA, MQTT, PROFINET, EtherNet/IP, Modbus TCP/IP
Edge computing and industrial gateway devices
Centralised dashboards with real-time plant status
Production data analytics and OEE tracking
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
AI-Powered Monitoring
PPE and safety gear detection (helmet, vest, shoes, gloves, harness)
Fire and smoke detection
Intrusion and restricted area monitoring
Vehicle tracking, speed monitoring, and ANPR
Crowd and occupancy management
Worker productivity analysis
Production counting and quality inspection
SAP integration and custom API connectivity
Real-time alerts via Email, WhatsApp, SMS, hooters
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Readiness
ISO 9001 - Quality Management Systems
ISO 45001 - Occupational Health and Safety
ISO 14001 - Environmental Management
IEC 62443 - Industrial Cybersecurity
ISA-95 - Enterprise-Control System Integration
ISA-88 - Batch Process Automation
Audit-ready documentation and automated reporting
Pre-certification readiness assessments
Compliance & Standards
Built to Meet the Standards
Your Industry Requires
Every system KGT deploys for steel and metal operations is designed to meet or exceed the compliance standards that govern your industry.
If your plant has gaps in any of the areas listed below, whether in safety documentation, environmental monitoring, traceability, or cybersecurity - our team will assess what is missing and build the infrastructure needed to support certification.
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Industrial Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
ISO 9001
- Quality Management Systems
ISO 45001
- Occupational Health and Safety Management
ISO 14001
- Environmental Management Systems
IEC 62443
- Automation and Control Systems Security
ISA-95
- Enterprise-Control System Integration
ISA-88
- Batch Control Standards
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
Vizibelt is an Ai-powered monitoring system designed for conveyor operations - detecting foreign objects in real time and preventing belt failures before they disrupt production.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
1+
1+
Reduction in Downtime
1%
1%
Increase in Productivity
1%
1%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Ready to discuss your
plant operations?
Deployed in Live Operations
•
Tata Steel
$86K+ Lost in 1 Month. Zero Since Vizibelt.
Connect to Content
Add layers or components to swipe between.
We built Vizibelt
An AI-powered monitoring system that detects foreign objects in real time and stops the belt before damage occurs.
Detected Foreign Object Incidents
0+
0+
Reduction in Downtime
0%
0%
Increase in Productivity
0%
0%
Industrial AI System
Computer Vision
IIoT
Modbus Protocol
PLC