AI-Powered Pipe Counting for Industrial Accuracy

Our Pipe Counting solution uses advanced computer vision and deep learning to automatically detect, classify, and count pipes in real-time — whether on a truck, in a yard, or on a production line. No more manual counting errors, no more wasted time.

Built for the pipe manufacturing and distribution industry, this solution works with live video feeds, captured images, or recorded footage, delivering accurate counts with confidence scores — even when pipes are stacked, overlapping, or partially occluded.

The Problem

Manual pipe counting is slow, error-prone, and labor-intensive. Workers spend hours counting pipes during loading, unloading, and inventory checks. A single truck carrying 500+ pipes can take 30–45 minutes to count manually — and miscounts lead to billing disputes, delivery shortages, and inventory discrepancies that cost businesses thousands every month.

The Solution

Our AI system leverages Faster R-CNN with Feature Pyramid Networks (FPN) to detect and classify pipes at multiple scales. Combined with SAHI (Slicing Aided Hyper Inference), the model accurately identifies pipes as small as 20px in dense, crowded frames — achieving 95%+ accuracy even in challenging industrial conditions.

The system processes each image in 2–5 seconds, supports interactive Region of Interest (ROI) selection for targeted counting, and automatically removes duplicate detections using adaptive NMS algorithms.

Key Metrics

How It Works

Point a camera at the pipes — our AI does the rest. The system uses a trained Faster R-CNN model to detect circular cross-sections of pipes in the frame, classifies each pipe by type, applies intelligent duplicate removal to avoid double-counts, and delivers a final tally with visual proof. Results are automatically exported to Excel and annotated images for audit trails.

Use Cases

Loading & Unloading Verification — Instantly verify pipe counts during truck loading/unloading to prevent shortages and disputes between suppliers and buyers.

Yard Inventory Management — Conduct rapid stock audits across pipe yards without shutting down operations. Count thousands of pipes in minutes instead of hours.

Production Line QC — Monitor output from production lines in real-time, tracking pipe counts per batch and flagging discrepancies automatically.

Dispatch & Billing — Generate tamper-proof visual evidence of pipe counts for invoicing, reducing payment disputes by up to 90%.

Technology Under the Hood

Powered by a state-of-the-art Faster R-CNN architecture with ResNet-50 FPN backbone, trained on thousands of real-world industrial pipe images. The model supports multi-class detection across 4 pipe categories and uses adaptive confidence thresholds for precision control. SAHI integration enables detection of small objects in high-resolution images by intelligently slicing frames into overlapping tiles.

Deployment Options

Deploy on-site with edge devices for real-time processing, use our desktop GUI application for immediate results, or integrate via our cloud API for batch processing. The solution scales from a single handheld device to multi-site deployments with centralized dashboards and analytics.

Return on Investment