AI-Powered Security Overhaul for a 12-Acre FMCG Manufacturing Plant

A leading FMCG manufacturer operating a 12-acre production campus in Delhi NCR had been running a 7-year-old analogue CCTV system with no analytics capability, significant blind spots across the production floor and zero perimeter coverage. The fire alarm panel had not been serviced in three years and had two known faults that remained unresolved. Following a significant raw material theft incident — estimated at ₹18 lakhs in a single weekend — management mandated a complete security infrastructure overhaul with a 30-day deployment deadline.

Pujaso began with a comprehensive 3-day site survey mapping all camera positions, perimeter zones, access points, fire zones and network infrastructure. The entire analogue system was decommissioned and replaced with a Hikvision IP camera network on a new structured cabling infrastructure.

120 Hikvision cameras were deployed: 48 in production areas (with PPE compliance detection configured to alert when workers enter zones without helmets or high-vis vests), 32 along the perimeter with AI line-crossing and loitering detection, 24 in warehouses and loading bays, and 16 across offices, entrance gates and car park. All cameras were connected to a 128-channel NVR cluster with 144 TB storage — providing 45 days of retention.

AutoSense™ was configured to monitor all camera feeds, correlate access control events with camera zones and auto-PTZ to any perimeter alert within 3 seconds. CCTV Health Monitoring was activated on day one — daily health reports and WhatsApp alerts for any camera or storage anomaly.

The fire alarm was replaced with a Telefire addressable system with 180 smoke and heat detectors across all buildings, tested and certified to BIS/NBC standards.