PPE detection that works on Indian shop floors, not just in demos
Most AI PPE detection systems look good in a clean demo and fall apart in a real plant: dust, glare, contractors in street clothes, workers partly hidden behind machines. Within a few weeks the alerts are ignored.
Neurabit VMS detects helmet, vest, gloves, boots and harness violations on your existing IP cameras, zone by zone and shift by shift, on hardware inside your plant. We tune it on your own footage until the alerts are ones your supervisors act on.
Key facts
- Neurabit VMS detects five PPE items on existing CCTV: safety helmet, high-visibility vest, gloves, safety boots and fall-protection harness.
- PPE detection in Neurabit VMS costs from ₹800 per camera per month on subscription, with edge hardware included, so 20 cameras cost ₹16,000 per month.
- Neurabit VMS targets under one false positive per camera per day on critical PPE alerts, and every rule shows its own measured false-positive rate.
- Each zone can require different PPE: a helmet rule in the press shop and a harness rule at height run independently on the same camera network.
- Neurabit VMS subscription starts at ₹800 per use case per camera per month with edge hardware included. To own the hardware instead, edge devices start at roughly ₹50,000 and each handles up to 10 cameras, with each use case licensed per camera on a perpetual or annual licence, priced on request. Discount tiers are available on request.
Why PPE detection pilots fail
PPE pilots almost never fail on detection accuracy. They fail on false positives. A system that is accurate on paper but fires forty false alerts per camera per day trains supervisors to ignore it within two weeks, and trust does not come back.
Neurabit VMS is built around that problem. Every rule shows its false-positive rate, you can replay a threshold change against the last 7 days of footage before committing, and the first 2 to 4 weeks of every deployment are spent tuning on your site's own conditions.
What it detects, and what is harder
Helmets and vests are the most reliable detections because they are large and high-contrast. Boots and harnesses are reliable when the camera can see the full body. Gloves are the hardest, because hands are small in the frame and often hidden behind work.
Camera placement matters more than the model. A camera mounted too high, or pointed into a bright doorway, will underperform no matter what runs on it. We tell you which cameras need moving during the site survey, before you spend anything.
How an alert works
- The camera sees a person in a zone that requires a helmet, during a shift when the rule is armed.
- The system confirms the violation across several frames to avoid one-frame false alarms.
- The zone supervisor gets a WhatsApp alert with the clip within seconds.
- If nobody acknowledges within the SLA, it escalates to the shift in-charge, then the plant head.
- The supervisor closes it with a reason code, so you end up with compliance data by zone, shift and contractor.
Evidence for audits and the OSH Code
The Occupational Safety, Health and Working Conditions Code, 2020, which replaced the Factories Act, 1948, came into force on 21 November 2025. It does not require AI monitoring, but it does make employers accountable for safe working conditions. Neurabit VMS gives you timestamped, exportable evidence of PPE compliance trends and near-misses by zone and shift, with a chain-of-custody record on every export.
Frequently asked questions
How accurate is AI PPE detection in dusty factories?
Helmets and vests are detected reliably in most industrial conditions once the system is tuned on site footage. Dust, glare and poor camera angles mainly raise false positives rather than cause missed detections, which is why the first 2 to 4 weeks are spent tuning. We target under one false positive per camera per day on critical alerts.
Can it detect PPE on contract workers who do not wear uniforms?
Yes. The system looks for the equipment itself, not uniform colours, so contractors in street clothes are detected the same way as permanent staff.
Does PPE detection work with our existing CCTV cameras?
Yes, with any ONVIF-compliant IP camera that provides an RTSP stream. Resolution and mounting angle decide how well it works, so we check each camera during the site survey.
What does PPE detection cost per camera in India?
From ₹800 per camera per month on subscription, with edge hardware included. If you want more than one use case on a camera, such as PPE plus fire and smoke, each adds ₹800. To own the hardware instead, edge devices start at roughly ₹50,000 and each handles up to 10 cameras, with each use case licensed per camera on a perpetual or annual licence, priced on request.
Does footage leave the plant?
No. Detection and recording run on edge hardware inside your plant. Only alert notifications leave the site, to recipients you configure.
Find out which of your cameras can run PPE detection
We tell you which of your existing cameras are usable before you spend anything, and a real engineer replies within one business day.
Request a site survey →Last updated 24 September 2026. Technical content reviewed by Abhishek Goel, Chief Technology Officer, Neurabit Solution.