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.

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Why miscounts cost manufacturers millions 

Manual counting is slow, error-prone and leaves blind spots 

Inaccurate counts hide what’s really happening

When counting relies on manual methods or basic machine/sensor data, it often fails to reflect the true number of units on the line; especially in complex food environments where only visual systems can reliably see empty trays, missing items, or misaligned products.

Variance in counts masks loss and improvement opportunities

Inconsistent or inaccurate counts across the production system obscure where product is being lost, which stages are underperforming, and where to focus improvement efforts, making it harder to optimise yield, labour, and materials.

Vision AI turns variance into actionable insight

By using vision-based counting alongside Quality and Label/Packaging AI agents, you can automatically reconcile produced units with quality and packaging rejects, revealing true good vs bad output and pinpointing the specific reasons for loss to drive continuous improvement.

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.

Book a Demo