SERVICE · PERCEPTION AI

Custom AI software for
industrial LiDAR & vision.

We build custom perception pipelines for industrial customers — 3D point-cloud classification, object detection, anti-collision and worker-safety monitoring. Five years of LiDAR engineering in active production sites, packaged as software you can deploy on your own plant.

5 yrs industrial LiDAR engineering
40+ live deployments
3D + 2D LiDAR & computer vision
K+S · Nordzucker · Aurubis production references
SERVICE  ·  Industrial perception AI · LiDAR + computer vision

Custom perception software, built by people who run it in production.

Industrial perception AI is software that turns raw 3D point clouds and 2D camera images into machine-readable decisions on a plant floor. We design, build and ship those pipelines for industrial customers — scrap-vs-slag classification, crane and vehicle detection, worker safety in ATEX zones, material-flow optimisation.

We started with one job: measuring stockpiles with LiDAR inside an active mining operation. Five years and forty live installations later, we have a deep toolbox for industrial point-cloud and computer-vision work — Riegl, Livox and Faro on the hardware side; PCL, Open3D, OpenCV and PyTorch on the software side; OPC UA, REST and MQTT into your control system. We bring that toolbox to your data.

We don't sell a generic AI platform. Every engagement starts with a short data audit: what sensors do you have, what does your data look like, what decision are you trying to automate? From there we propose a fixed-scope pipeline — typically 4–12 weeks from contract to live tool. For larger programmes we move into a monthly retainer model with shared road-mapping. Either way you own the code: see our FAQs on IP and hardware reuse for the standard terms.

„If we can run it on our own mining site, we can run it on yours."

Production references across salt, sugar, copper, charcoal and minerals.

Three problem clusters

What we build — in three clusters.

Material classification

Scrap-vs-slag classification on steel-mill yards, ore-grade detection on conveyors, mixed-material search and segmentation on stockpiles. Point-cloud classifiers and 2D vision models trained on your material — not a public benchmark.

Asset tracking

Crane position + anti-collision in waste bunkers and warehouses, vehicle detection at plant gates and weighbridges, railcar and wagon recognition for loading automation. LiDAR-based, lighting-independent, works in dust.

Safety & compliance

Worker detection inside ATEX zones and around moving plant equipment, safety-distance monitoring on automated cranes and AGVs, hazard-zone clearance checks before a process restart. Auditable event logs included.

Engagement model

Three ways to work with us.

No long sales cycles. We scope every engagement around your data — start with a workshop, move to a fixed-scope project, optionally into a long-term retainer.

01

Discovery & Assessment

A 1–3 day on-site or remote workshop. We audit your sensors, your data pipeline and the decision you want to automate, and ship a written feasibility note with a recommended next step. Starting at a few days. Fixed price.

02

Custom Pipeline / Tool

A 4–12 week project that delivers a working perception pipeline — data parser, detection/classification algorithm, dashboard or OPC UA integration into your control room. Fixed scope, fixed price, you own the code at handover.

03

Long-term Partnership

A monthly retainer for ongoing model retraining, sensor migrations, new use cases and on-call support. The right fit when you want a perception engineering team without hiring one. Quarterly road-mapping.

All three tiers include source code, documentation and a written handover — no black boxes, no licence dependence on us.

Use cases · #use-cases

Six places where perception AI earns its keep.

Scrap-vs-slag classification

Distinguish ferrous scrap from cooled slag on a steel-mill yard, in real time, from a portal-mounted LiDAR + camera pair. Feeds the EAF charging schedule and reduces sorting labour on the yard. Read the deep dive →

Material flow optimisation

Continuous classification of bulk material on conveyors and at transfer points — feeds blending models, prevents off-spec batches and gives the control room a real material-balance instead of an inferred one. Read the deep dive →

Crane detection & anti-collision

LiDAR tracks crane bridge, trolley and hook position in a waste bunker or warehouse. Drives anti-collision interlocks, optimises grab routing, integrates with the crane PLC over OPC UA. See OWL EYE® Waste Bunker for a productised version. Read the deep dive →

Vehicle detection

Truck, loader and forklift recognition at plant gates, in-plant intersections and weighbridges. Drives gate control, traffic-light interlocks and in-plant routing — works at night, in fog and in dust. Read the deep dive →

Railcar & wagon recognition

Detect, count and identify railcars at a loading station. Drives automated loading sequences, prevents misroutes and feeds a per-wagon material log into ERP. Read the deep dive →

Worker detection & ATEX zones

Person detection in hazard zones — ATEX areas, swing radius of cranes, conveyor pull-cords. Triggers slowdowns, hard stops or audible warnings. Auditable event log for the safety officer. Read the deep dive →

Stack we use

Mature tools — industry-standard, not experimental.

We keep the stack boring on purpose. Every library on this list has a multi-year track record in industrial production environments.

Point cloud
PCL, Open3D
Computer vision
OpenCV
Deep learning
PyTorch
Languages
Python, C++
Deployment
Docker, Linux, Windows
Robotics middleware
ROS / ROS 2
Plant integration
OPC UA, MQTT, REST, Analog out
LiDAR sensors
Riegl, Livox, Hesai, Ouster, Veyond, Faro
Cameras
Basler, FLIR, Allied Vision, IDS
See it run

Live detection — single scan, six lids, two seconds.

The Electron UI as the plant operator sees it: load a freshly arrived scan, the algorithm classifies the point cloud into ground, wagon body and lid cluster, projects centerpoints and updates the train log. All stateless on the algorithm side — the tracker is a separate state machine.

How we scope a project →
FAQ

Questions about custom perception AI.

Industrial Perception AI

What does custom perception AI software cost? +
We don't publish list prices because every project is scoped against your data and your decision logic — but we work to three predictable tiers. Discovery & Assessment — a 1–3 day workshop, on-site or remote, fixed price in the low-four-figure range. You receive a written feasibility note, a recommended next step and (if applicable) a fixed-price quote for the follow-on project. Useful even if you don't then go ahead — many customers use the note to evaluate two or three vendors. Custom Pipeline / Tool — a 4–12 week project delivering a working perception pipeline (parser + algorithm + dashboard or OPC UA integration). Fixed scope, fixed price, you own the code at handover. Typical project size is in the mid-five to low-six-figure range depending on data volume, sensor count and integration depth. Long-term Partnership — a monthly retainer for ongoing development and on-call support. Sized to the team capacity you need (typically 0.5–2 FTE equivalent). Quarterly road-mapping included. All three tiers include source code, written documentation and a clean handover — no licence dependence on us. See our Industrial Perception AI service for the full engagement model.
How long does it take to build a custom perception pipeline? +
From signed contract to a working tool in production, expect 4–12 weeks for a standard custom-pipeline engagement. The spread is driven by three factors. Data readiness. If you already have labelled data or representative recordings, we start training in week 1. If we need to set up data collection, add a sensor, or label from scratch, the front end adds 1–3 weeks. Integration depth. A standalone dashboard with REST output is the fastest path — typically 4–6 weeks. OPC UA integration into a running control system, with interlocks, factory-acceptance tests and a customer change-management process, is closer to 8–12 weeks. Sensor count and site complexity. One LiDAR + one camera in a clean indoor environment is faster than a six-sensor outdoor portal with dust, snow and dynamic lighting. We scope the difference up-front in the Discovery workshop. For a faster first signal we recommend the Discovery & Assessment tier — 1–3 days, fixed price, written feasibility note within a week. See Industrial Perception AI for the full model.
Who owns the code and IP we pay you to build? +
You do. Our standard contract transfers full ownership of the project-specific code, model weights, training data (where the data is yours) and documentation to you on final acceptance. We don't keep a back-door licence and we don't lock you into a maintenance contract. What we retain is our pre-existing toolbox — reusable libraries, calibration utilities, generic data parsers, the OWL EYE® core — which we license to you, royalty-free, for use on the delivered tool. This is the same boundary that any reputable engineering firm draws: we bring the toolbox, you keep the deliverable. If you want a different IP arrangement — for example a joint patent on a novel algorithm, or a co-developed model that we both reuse with consent — we structure that explicitly in the project contract. Tell us up-front in the Discovery workshop. Full engagement details on our Industrial Perception AI page.
Can you use our existing cameras and LiDAR sensors? +
Yes — in most cases. Our toolchain is sensor-agnostic on the data layer. If your sensors deliver a standard format (PCD, LAS, E57 for point clouds; RTSP, GigE Vision, USB3 Vision for cameras) we can ingest them in a day. We've worked with Riegl, Livox, Faro, Hesai, Velodyne, Ouster, Basler, FLIR, Allied Vision and IDS cameras. We'll tell you honestly when the existing hardware isn't the right tool. Common cases where we recommend a replacement: - The existing LiDAR is too narrow (FoV or range) to cover the area you want classified — usually solved by repositioning before buying anything new. - The camera is auto-exposing on a high-contrast scene (sun + shadow at a gate), which breaks classification reliability — solved by switching to a manual-exposure industrial camera with HDR sensor. - The existing sensor's vendor lock-in (proprietary stream format, no documented SDK) makes integration cost more than a Livox replacement. We don't earn a margin on reselling hardware to you. If you do want us to source new sensors, we do that through our normal Hardware & products channel at list price. See Industrial Perception AI for how we scope it.

Tell us about your data.

A short call, a few sample files or a sensor stream — we come back within two business days with a written feasibility note and a fixed-price scope for the discovery workshop.

info@sachtleben-technology.com +49 7831 969 22-190
Send us a message

Tell us about your perception task.

Sensor setup, sample data, the decision you want to automate — anything you have. We come back within two business days with an honest first assessment and a fixed-price scope for the Discovery workshop.

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Sachtleben Technology GmbH
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