Frito Lay

Automated palletizers are a key part of manufacturing. Companies like Frito-Lay use them to keep packaging lines moving fast. But when a palletizer breaks down, the problem spreads quickly. One jammed or dropped case can cause product to pile up, stop the entire line, and require a lengthy cleanup.

To limit these slowdowns, Frito-Lay assigned workers to physically watch the palletizers. This helped catch problems faster, but it also meant using people to watch machines, which defeated the purpose of the automated process.

DSI solved this problem by installing a surveillance camera solution built specifically for manufacturing environments. Using high-resolution cameras from Avigilon, operators can now watch multiple palletizers simultaneously from a single workstation. The cameras show clear, live video of how pallets are being built, how products are flowing, and where jams might be forming.

Beyond live video, Avigilon’s smart analytics detect unusual activity around the machines and send alerts when something needs attention. This allows workers to respond quickly to problems without having someone stationed at every machine.

The outcome: problems are spotted faster, production downtime is reduced, and workers are used more effectively. Facilities get the full benefit of automation while still keeping a close eye on operations.

Today’s surveillance camera solutions do much more than traditional security work. In manufacturing, these systems have become essential operational tools. They give teams real-time visibility into automated processes and send alerts the moment something looks wrong. Instead of reviewing footage after a problem already happened, DSI’s camera solutions now help manufacturers catch issues early, respond faster, and keep production on track.