Vecoplan introduces an early fire detection system

Vecoplan is expanding its range with Hotspot Monitoring, a thermal imaging system that uses artificial intelligence to detect dangerous temperature rises in recycling plants at an early stage. The solution is intended to identify overheating hotspots before they develop into fires. According to data provided by the company, approximately 10,000 fires are recorded every year at waste processing plants in Germany, and this number is steadily increasing. Incorrectly disposed of lithium-ion batteries are considered the main cause, as they can be damaged and ignite during the recycling process.

Battery-powered devices such as smartphones, power tools and e-cigarettes sometimes enter general waste instead of the appropriate collection streams. If the casing of a lithium-ion battery is damaged during processing, the battery may react and ignite. The material may also heat up after a delay, which means that critical changes are initially not visible.

Hotspot Monitoring uses a dual-spectrum thermal imaging camera that monitors designated areas across a large surface and provides both a thermal image and a camera image. If the temperature in the monitored zone exceeds defined limits, the system triggers an alarm. Monitoring can cover not only belt conveyors but also material flows, stockpiles, feed hoppers and material feed lines. The sensor is installed outside the material stream, so it is not exposed to mechanical wear and is less susceptible to contamination.

The AI-based thermal imaging system monitors not only belt conveyors but also material flows, stockpiles, feed hoppers and material feed lines

Image analysis reduces false alarms

Conventional solutions measure temperature but do not take account of the context of the observed event. Heat emitted by vehicles or exhaust gases may therefore be incorrectly identified as a fire source, even though the monitored material has not reached a critical temperature. The AI-based image recognition used in Hotspot Monitoring is designed to distinguish between such cases and reduce the number of false alarms.

Individual areas of the material feed line can be configured so that the presence of forklift trucks or wheel loaders does not trigger an alarm. "Many plants already have temperature sensors, but only a few have a system that understands the context," explains Paul Mockenhaupt, Head of Automation Technology at Vecoplan. "This is precisely the key difference. Hotspot Monitoring detects not only heat but also potential hazards."

Integration with Vecoplan Smart Center

Hotspot Monitoring is integrated with Vecoplan Smart Center, a digital platform for real-time data processing and remote access. The system enables continuous temperature measurement within defined monitoring zones. It can also operate if the internet connection fails because it is connected to the platform but does not depend on internet access.

The control unit processes alarm signals and temperature data, while VSC.router provides a secure IT connection. The solution enables remote support, including during event analysis. When an alarm is triggered, authorised employees can access the system directly and analyse the situation immediately.

Vecoplan offers solutions covering successive stages of material processing, from shredding through conveying and screening to cleaning technologies. The thermal imaging system complements this architecture by combining monitoring, automation and service support. The camera can also be installed as part of a retrofit of an existing system and integrated with different systems.

With Hotspot Monitoring, Vecoplan addresses a gap in early fire detection at recycling plants