Project Scope & Business Context
KAS Info Tech (ISO 9001:2015, GeM‑empanelled) has deployed over 850 CCTV sites for Rajasthan Police, Alwar Railway Station, DMart, Blinkit dark stores, Pepsi India and Metso India. This guide leverages that experience for manufacturing plants in the Bhiwadi‑Neemrana‑Alwar industrial corridor.
1. Perimeter Defense Strategy
Goal: Detect intrusion before a breach reaches the production floor. Recommended layers:
- Outer fence (30 m × 30 m grid) – 4‑MP PTZ cameras with 120° horizontal FOV, mounted 12 m high.
- Gatehouse – Dual 5‑MP fixed dome with IR, positioned 8 m high, covering vehicle lanes.
- Blind‑spot corners – 3‑MP bullet with built‑in heater for winter fog.
All cameras must meet IP66 dust rating and have a minimum operating temperature of –30 °C to survive Rajasthan’s summer heat and dust storms.
2. Shop‑Floor Camera Selection
Manufacturing floors generate dust, metal shavings and occasional oil mist. Choose cameras with:
| Camera | Resolution | Dust Rating | Low‑Light | Price (₹) |
|---|---|---|---|---|
| Hikvision DS‑2DE4A425IW‑DE (4 MP PTZ) | 4 MP (2560×1440) | IP66 | Thermal IR 30 m | 12,500 |
| CP Plus CP‑TH‑5MP IR Dome | 5 MP (2592×1944) | IP66 | Color Night Vision 20 m | 9,800 |
| Dahua N52A (2 MP Fixed) | 2 MP (1920×1080) | IP66 | IR 25 m | 5,200 |
For high‑risk zones (laser cutting, welding), add a thermal camera (Hikvision DS‑2TD2617B‑10) at ₹18,000 each.
3. Camera Height & Angle Calculations
Formula: H = (D × tan(θ/2)) / tan(α/2) where H = mounting height, D = coverage width, θ = horizontal FOV, α = desired vertical coverage angle.
Example – 4‑MP PTZ (θ=120°) covering a 15 m wide conveyor with a vertical view of 8 m:
- α = 60° (typical for floor monitoring)
- H = (15 × tan60°) / tan30° ≈ (15 × 1.732) / 0.577 ≈ 45 m → impractical.
Solution: Reduce coverage width to 8 m or use a 2‑MP fixed dome (θ=90°). Re‑calc:
- H = (8 × tan45°) / tan30° ≈ (8 × 1) / 0.577 ≈ 13.9 m → round to 14 m.
Mount 14 m high on a steel truss; angle the lens 15° downward to keep the focal plane at 2 m above the floor, ideal for detecting personnel and equipment movement.
4. NVR Architecture & Redundancy
Recommended core: Dual‑node NVR cluster with automatic failover.
| Component | Model | Channels | RAID | Price (₹) |
|---|---|---|---|---|
| Primary NVR | Hikvision DS‑7732NI‑I4/8P | 32 (8 MP + 24 IP) | RAID5 (8 TB) | 85,000 |
| Secondary NVR (Hot‑Standby) | Same as Primary | 32 | RAID5 (8 TB) | 85,000 |
| SSD Cache | Samsung 970 EVO 1 TB | — | — | 12,000 |
Both NVRs connect to a dedicated 1 Gbps fiber link to the control room. Use VRRP (Virtual Router Redundancy Protocol) so the secondary takes over within 2 seconds of primary failure.
5. Cabling, Power & Network Design
- Use Cat6a shielded cable for PoE+ (802.3bt) up to 100 m.
- Deploy industrial‑grade UPS (2 kVA) per NVR rack for 30 min runtime.
- Implement surge protectors (IP68) at every camera junction box.
- Run conduit in steel trays to meet local fire codes.
6. Cost Estimate (Typical 150‑Camera Plant)
| Item | Qty | Unit Price (₹) | Total (₹) |
|---|---|---|---|
| 4‑MP PTZ (perimeter) | 20 | 12,500 | 250,000 |
| 5‑MP IR Dome (shop‑floor) | 80 | 9,800 | 784,000 |
| 2‑MP Fixed (aux) | 30 | 5,200 | 156,000 |
| Thermal Cameras | 5 | 18,000 | 90,000 |
| Primary NVR | 1 | 85,000 | 85,000 |
| Secondary NVR | 1 | 85,000 | 85,000 |
| SSD Cache | 2 | 12,000 | 24,000 |
| Cabling & Power | — | — | 150,000 |
| Installation Labor | — | — | 120,000 |
| Grand Total | 1,804,000 | ||
All prices reflect KAS Info Tech’s official 2026 price list (ShopTec line). Discounts of up to 10 % apply for bulk orders (>200 cameras) or government tenders (GeM).
7. Implementation Checklist
- ☑ Conduct site survey (KAS Info Tech line +91 80581 22230).
- ☑ Finalize camera layout using CAD overlay.
- ☑ Verify power budget (PoE + UPS capacity).
- ☑ Install conduit and pull Cat6a cables.
- ☑ Mount cameras at calculated heights; set tilt angles.
- ☑ Configure NVR cluster, enable VRRP, set RAID.
- ☑ Test video streams for latency (<200 ms) and storage retention (30 days).
- ☑ Handover documentation and train plant security staff.
8. Expert Callout
Pro tip from KAS Info Tech’s senior systems architect: In dust‑heavy zones, add a 2‑mm poly‑carbonate shield over the lens and schedule quarterly cleaning with a low‑pressure air blower. This extends camera life by up to 30 % and maintains IR performance.
For a detailed proposal, contact KAS Info Tech 24/7 helpline +91 80581 22233 or WhatsApp line +91 80581 22230.
Frequently Asked Questions
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KAS Info Tech delivers certified enterprise surveillance, fiber optic backbones, and biometric security systems across Rajasthan and Pan-India. Contact our engineering team for a free site audit.