Shop-floor Air Quality & Compliance

Remote Monitoring & IoT · MI-RM-03

LoRaWAN air-quality sensors in welding, painting and grinding zones, a gateway, and a dashboard that reports CO₂, particulate and VOC exposure by zone with alerts when ventilation should be increased.

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• ₹41,200pilot BOM · hardware only
• 2 – 3 daysto a live pilot
• Starterintegration level
• 3validated providers

Why a yearly survey is not an exposure record

The problem

Welding, painting, grinding and battery-charging zones have no live record of what the air actually contains. Ventilation runs on a timer, complaints are anecdotal, and the safety file has a once-a-year third-party survey instead of continuous exposure data.

• No live CO₂, PM2.5/PM10 or VOC data per zone
• Ventilation is scheduled, not driven by conditions
• Exposure-hours cannot be shown for audits or worker health records
• Poor air quality shows up as fatigue, complaints and absenteeism

The solution

Two multi-parameter air-quality sensors (CO₂, PM2.5/PM10, VOC, temperature, humidity) report over LoRaWAN to a gateway. A dashboard shows a zone-wise air-quality index, accumulates exposure-hours above limits and alerts the supervisor when ventilation should be increased or a zone cleared.

• Zone-wise AQ index updated every few minutes
• Exposure-hours report per zone per shift for EHS records
• Alerts to supervisors when limits are approached
• Data to right-size ventilation instead of running it on a timer

Validated service providers

Validated by TwoElectrons and ranked by validation score: verified credentials, completed jobs on the platform and client ratings.

1. Sample Provider A — Pune · LoRaWAN sensing & dashboards · ★ 4.8 · 14 jobs
2. Sample Provider B — Bengaluru · Energy & utilities IoT · ★ 4.7 · 11 jobs
3. Sample Provider C — Coimbatore · Plant environmental monitoring · ★ 4.6 · 8 jobs

Provider listings are samples pending live registrations.

Pilot BOM and cost

Reference hardware to run the pilot. Unit costs are indicative Indian market prices for the component class.

POC BOM cost only — hardware for a pilot. Installation, integration and provider services are quoted separately. Request for Quote

How zone air-quality monitoring works

1. Place. Wall-mount two sensors in the highest-exposure zones.
2. Connect. Plug in the gateway; sensors join over LoRaWAN.
3. Set limits. Enter CO₂, PM and VOC thresholds with EHS.
4. Report. Run three weeks; review exposure-hours and ventilation timing.

Pilot architecture

2× Air-quality sensors (CO₂ · PM · VOC · T/H) → LoRaWAN indoor gateway → Cloud LNS + AQ platform (index · exposure-hours) → EHS dashboard (alerts · shift reports)

Two zones on one gateway; scale to every zone with a sensor each.

Business case: exposure-hours, ventilation, compliance

Ranges are typical figures reported for this class of solution; your pilot establishes the numbers for your plant.

• Continuous exposure record per zone (versus one annual survey)
• Minutes to a ventilation alert (when a zone exceeds limits)
• Per shift exposure-hours report (for EHS and worker health files)
• 2 – 3 days to a live pilot (two zones, one gateway)

Who this is for: EHS / safety heads, Plant managers, Fabrication, welding and paint shops, Foundries and grinding shops, Battery and chemical handling areas, Any plant with occupational exposure limits to meet.

Illustrative case study

Illustrative scenario · not a client reference

A fabrication shop with a welding bay and paint booth in Coimbatore (illustrative)

Set-up. One sensor in the welding bay and one at the paint booth exit, gateway in the shop office, dashboard shared with the EHS officer and shift supervisors.

What happened. PM2.5 in the welding bay was above the internal limit for roughly two hours each afternoon when extraction was switched to half speed to save power. Extraction was re-scheduled by sensor reading instead of by clock, cutting exposure-hours by about 70% without raising the energy bill.

• Pilot budget: ₹41,200 hardware
• Exposure-hours cut: ~70%
• Ventilation change: condition-driven

FAQ

Which parameters does the sensor measure?

CO₂, PM2.5 and PM10, total VOC, temperature and humidity in one unit; specialised gases (CO, NO₂, O₃) are optional add-ons.

How accurate are the sensors compared with a survey instrument?

They are indicative-grade sensors intended for continuous trend and alerting, not certified reference instruments; they show when and where to investigate and give continuous records between surveys.

Can it control the ventilation directly?

In the pilot it alerts people; a scale-up phase can drive VFDs or dampers through the gateway's relay or Modbus output.

What does the ₹41,200 cover?

Two sensors, one gateway and wall-mount kits on a free-tier dashboard. Installation, reports and provider services are quoted after a Request for Quote.