Count every product with real-time vision AI
The Thingtrax counting agent gives food manufacturers instant visibility into every unit produced – eliminating miscounts, boosting yield, and ensuring accurate shipments.
Why miscounts cost manufacturers millions
Manual counting is slow, error-prone and leaves blind spots
Undercounts distort yield and inventory accuracy
Overcounts lead to overproduction and waste
Missed units cause shipment errors and planning chaos
Thingtrax makes miscounts and errors obsolete
Thingtrax’s counting agent uses vision AI to track every product in real time – no sampling, no blind spots. It ensures 100% unit visibility, accurate throughput data, and automated alerts when counts deviate from expected targets.
Features that deliver measurable impact
Real-time Product Tracking
Every unit counted as it moves down the line
Yield Optimisation
Prevents loss and improves production efficiency
No Process Changes
Works with your existing line and hardware
Anomaly Alerts
Detects undercounts and overcounts instantly
Live Dashboards
Accurate throughput data for planning and reporting
Fast ROI
Install in days or weeks, see results quickly
Why Thingtrax is the best solution
Traditional Counting Systems
(IoT / Sensor-based)
Thingtrax Vision AI
Product Counting
Detection Method
Traditional Counting Systems
(IoT / Sensor-based) :
Uses IR, laser, or proximity sensors to detect product presence
Thingtrax Vision AI
Product Counting :
Camera-based visual counting powered by AI object detection
Setup Requirements
Traditional Counting Systems
(IoT / Sensor-based) :
Requires precise sensor positioning and calibration for each product type
Thingtrax Vision AI
Product Counting :
Mount camera anywhere with view of conveyor – no mechanical alignment
Accuracy in Challenging Conditions
Traditional Counting Systems
(IoT / Sensor-based) :
Fails with shiny, transparent, or irregular surfaces causing false triggers
Thingtrax Vision AI
Product Counting :
Works in dusty, shiny, or variable lighting environments using vision intelligence
Handling of Overlapping or Irregular Products
Traditional Counting Systems
(IoT / Sensor-based) :
Cannot handle overlapping or multi-row products – frequent miscounts
Thingtrax Vision AI
Product Counting :
Counts overlapping or irregular products by visual separation in real-time
Adaptability to Line Speed Changes
Traditional Counting Systems
(IoT / Sensor-based) :
Requires manual tuning when conveyor speed changes
Thingtrax Vision AI
Product Counting :
AI automatically adjusts to speed changes without re-tuning
Maintenance
Traditional Counting Systems
(IoT / Sensor-based) :
Frequent cleaning and recalibration required due to dust or vibration
Thingtrax Vision AI
Product Counting :
Self-calibrating system; minimal cleaning or service required
Response to Sensor Failures
Traditional Counting Systems
(IoT / Sensor-based) :
Single-point sensor cannot see – blind when product overlaps or diverts
Thingtrax Vision AI
Product Counting :
Keeps counting visually – camera ‘sees’ every product
Installation Effort
Traditional Counting Systems
(IoT / Sensor-based) :
Needs sensor brackets and physical alignment on the line
Thingtrax Vision AI
Product Counting :
Simple plug-and-play installation – no line modification needed
Integration with Existing Lines
Traditional Counting Systems
(IoT / Sensor-based) :
Limited integration – mostly
digital I/O to PLC
Thingtrax Vision AI
Product Counting :
Easily integrates with PLC or MES
via API or digital signal output
Data & Reporting
Traditional Counting Systems
(IoT / Sensor-based) :
No visual record; only counter values displayed locally
Thingtrax Vision AI
Product Counting :
Live dashboard with count trends, throughput analytics, and video evidence
Changeover Between Products
Traditional Counting Systems
(IoT / Sensor-based) :
Manual adjustment required for every new product type
Thingtrax Vision AI
Product Counting :
New product types trained remotely; model deployed in minutes
Remote Monitoring & Support
Traditional Counting Systems
(IoT / Sensor-based) :
Requires physical access to sensor for troubleshooting
Thingtrax Vision AI
Product Counting :
Full remote diagnostics and support through cloud interface
Cost
Traditional Counting Systems
(IoT / Sensor-based) :
Low individual cost, but frequent maintenance increases downtime
Thingtrax Vision AI
Product Counting :
Low-cost camera + AI edge box with minimal maintenance
Scalability
Traditional Counting Systems
(IoT / Sensor-based) :
Each line requires separate sensors
and logic configuration
Thingtrax Vision AI
Product Counting :
Same model can monitor multiple lines or sites – highly scalable
Result
Traditional Counting Systems
(IoT / Sensor-based) :
Good for simple counting, unreliable for complex or variable lines
Thingtrax Vision AI
Product Counting :
Accurate, visual, and intelligent counting built for real-world conditions
Proven results from the factory floor
‘AI algorithms have increased production line efficiency by an average of 20% across food factories.’
Gitnux Report on AI in Food Manufacturing, 2025
Thingtrax’s vision AI agent
helps manufacturers achieve this uplift by eliminating miscounts, boosting yield, and ensuring every unit is accounted for in real time.
Ready to see thingtrax in action?
See how specialised food manufacturing AI agents deliver instant impact.
