The Problem
We worked with a large-scale manufacturer that manages hazardous gases across multiple production zones. Their legacy system had:
- No real-time gas leak alerts
- Manual-only worker incident tracking
- No mobile visibility for safety teams
- Difficulty scaling to new factory locations
They needed a customizable, mobile-first, and scalable solution.
The Solution: Modular AIoT Deployment
We co-developed a custom gas detection system using edge + cloud components:
- Fixed and portable sensors for CO, NO₂, CH₄ detection
- Wearable tags with fall detection via motion sensing
- Edge gateways pushing real-time MQTT events
- Mobile dashboard + alert routing
- Auto-escalation logic for critical events (voice alerts, sirens)
- Weekly compliance reports via cloud reporting module
Sensor latency: ~2.5 seconds from detection to mobile alert.
Key Metrics
| Metric | Result |
|---|---|
| Zones covered | 4 |
| Gas sensors deployed | 60+ |
| Wearable tags | 30 |
| Daily active users | 120+ |
| Response time improvement | ↓ 62% |
| Deployment time | ~4 weeks |
Engineering Takeaways
- Edge-side filtering reduces false alarms & saves bandwidth
- BLE + MQTT stack** enables lightweight, multi-zone design
- Custom hardware = better sensor layout fit & environmental tolerance
- Mobile UX increases on-site adoption and supervisor engagement
Want the Full Architecture + Deployment Details?
The diagram below shows how our system is structured:
Check out the complete case study here:
👉 [https://zediot.com/case/manufacturing/custom-gas-detection-system]
Or explore our AIoT SaaS platform at:
👉 [https://zediot.com/]
Have thoughts or similar projects? Drop them in the comments below.