Project Overview
- Client: Autosmart International
- Location: Staffordshire, England
- Industry: Automotive Chemical Manufacturing
- Lead Installer: Richards CCTV (West Midlands)
- Technology Partner: Dahua Technology
- Key Equipment Deployed:
- 1 x 64-Channel Network Video Recorder (NVR) (DHI-NVR616-128-4KS2)
- 8 x ATEX-Certified Explosion-Proof Bullet Cameras (DH-ECA3A1404-HNR-XB)
- 51 x Pro-Grade Bullet Cameras (DH-IPC-HDW3541T-ZS-S2)
- 2 x 360º Fisheye Cameras (DH-IPC-EBW8842-AS)
- 2 x Turret Cameras (IPC-HDW3549TM-AS-LED)
- 6 x 24-Port Power over Ethernet (PoE) Switches
Background
Autosmart International is a leading UK manufacturer of vehicle cleaning materials. At their expansive facility in Staffordshire, operations involve the large-scale manufacturing and storage of volatile cleaning chemicals. In industrial environments where flammable vapours, gases, and combustible dusts are present, standard commercial security cameras can present a serious hazard; even a minor electrical spark or heat build-up from a camera’s daily operation could potentially trigger a catastrophic incident.
To protect their staff, secure their high-value inventory, and maintain strict health and safety compliance, Autosmart required a highly specialised physical security integration.
The Challenge
The project presented three primary operational and engineering hurdles:
- Hazardous Atmosphere Compliance: Any electrical hardware installed inside the manufacturing and chemical storage zones had to be strictly intrinsically safe. Standard commercial CCTV was not an option; the environment legally demanded ATEX-rated, explosion-proof technology.
- Sprawling Storage Layouts: The storage areas feature high-density racking, narrow aisles, and heavy machinery, including high-reach forklift trucks loading and unloading large Intermediate Bulk Containers (IBCs) of volatile chemicals. The security setup had to provide flawless visual coverage of these narrow corridors without creating a blind spots.
- Complex Site Refurbishment: The installation had to take place while the existing manufacturing unit was undergoing a major live refurbishment to link it to a brand-new, purpose-built warehouse facility. Physical site access for the engineering team was highly restricted.
The Solution
Richards CCTV designed and engineered a bespoke, enterprise-grade security network utilising Dahua Technology’s advanced AIoT product range. We recommended Dahua based on our long-standing engineering partnership, the proven reliability and cost-effectiveness of their systems, and their extensive range of specialised industrial products.
1. Intrinsically Safe ATEX Surveillance
In the chemical manufacturing and volatile storage rooms, we deployed 8 ATEX-certified bullet cameras. These explosion-proof units are engineered with heavy-duty explosion-proof enclosures. They are physically designed to completely contain any internal sparks or heat generated during normal camera operation, preventing them from escaping and igniting flammable vapours in the surrounding atmosphere.
2. Wide-Area and High-Rack Coverage
To overcome the physical obstacles of narrow, high-rack aisles:
- We strategically installed 360-degree fisheye cameras. These wide-angle sensors allow us to cover massive warehousing expanses with a minimal number of cameras, reducing infrastructure costs.
- High-definition bullet and turret cameras were positioned down racking corridors to monitor the safe transit of high-reach forklifts and the handling of Intermediate Bulk Containers (IBCs).
3. Perimeter and Boundary Deterrence
To protect the site’s exterior, high-resolution pole-mounted cameras were situated around the perimeter of the Staffordshire site. These cameras actively monitor all commercial entrances, exits, and staff car parks to act as a powerful visual deterrent against trespassers and out-of-hours security breaches.
4. Unified Network Architecture
To power and manage this massive 63-camera system on a single, streamlined platform:
- We installed a robust Dahua 64-channel Network Video Recorder (NVR) to centralise video storage and system access.
- The system is powered entirely via 6 x 24-Port Power over Ethernet (PoE) Switches. This allowed our team to run both power and data to each camera through a single network cable, completely eliminating the need to install expensive local 240v power outlets at each camera location.
The Engineering Standard
Executing an industrial installation of this scale requires elite engineering discipline. Our teams worked to exceptionally strict regulatory standards to ensure the integrity of the ATEX certifications was preserved during the wiring and mounting phases.
“The client stipulated that any equipment installed in the potentially explosive areas had to be ATEX-rated, so creating cable routes and the mounting of the cameras had to be done to a high standard and to very strict regulations. Another challenge of the project which we successfully met was the difficulty of access by the installation team, as the manufacturing unit was undergoing refurbishment so that it could be linked to a new purpose-built warehouse facility.” — Jordan Marshall, Installation Manager at Richards CCTV
The Result & Operational Impact
By partnering with Richards CCTV, Autosmart International successfully secured their state-of-the-art Staffordshire premises while meeting every regulatory compliance standard:
- Airtight Health & Safety Monitoring: The ATEX-certified system guarantees intrinsically safe security monitoring in high-risk zones, keeping workers safe and fully aligning with UK health and safety regulations.
- AI-Driven Incident Recovery: Dahua’s built-in AI and advanced software enable the operations team to use smart event search functionality. This allows managers to search for specific incidents in seconds, drastically cutting down administrative review times.
- Automated Surveillance: AI functionality allows for automated monitoring of sensitive, high-risk areas of the chemical facility without requiring constant human monitoring.
Secure Your Industrial Premises with Richards CCTV
Whether you operate a small local business or manage a sprawling, nationwide chemical manufacturing facility, physical security is a critical long-term operational asset. At Richards CCTV, we look at your site risks objectively, ensuring your business is fully protected, legally compliant with British Standards, and optimised for maximum operational safety.
Request an Objective Assessment: Ready for a professional evaluation of your site risks? Contact Richards CCTV Today to book a consultative, no-obligation site survey with our experienced engineering team.