In recent years, thermal cameras have developed from specialised niche solutions into indispensable tools for industry, security and building management. Their key advantage lies in the contactless detection of thermal radiation, which enables even the smallest temperature deviations to be detected at an early stage. In production halls, critical hotspots on motor bearings, switch boxes or cable bundles can be identified at an early stage, before costly failures occur. Thermal cameras also provide reliable image data during night-time inspections or in difficult visibility conditions such as smoke or fog – without the need for additional lighting equipment. They are also becoming increasingly important in building energy consulting: drone flights with mounted infrared sensors reveal thermal bridges and leaks in insulation and facade surfaces without the need for scaffolding or time-consuming on-site inspections.
At the same time, companies and users must consider the associated challenges: High-resolution thermal cameras with precise calibration and radiometry are significantly more expensive than simple infrared guns or conventional digital cameras and require regular maintenance and recalibration to achieve reliable measurement results. Cheaper models, on the other hand, often only provide rough temperature readings with a measurement accuracy of ±2°C or more, which is insufficient in highly sensitive application scenarios. In addition, interpreting thermal images requires in-depth expertise: Not every heat source necessarily indicates a defect, as reflections, environmental conditions or material differences can distort the temperature image. In public or semi-public spaces in particular, the use of thermal cameras must be assessed in terms of data protection law and should be accompanied by transparent usage guidelines to avoid misunderstandings as a surveillance tool.
Manufacturer-neutral application scenarios
A typical application for thermal cameras is preventive maintenance in production plants: here, cameras continuously monitor press-sensitive equipment such as welding robots, conveyor systems or storage platforms and report temperature increases at critical points. If a predefined temperature threshold is exceeded, the system can be shut down automatically or maintenance teams can be alerted, thus avoiding unplanned downtime and expensive repairs. In the energy sector, thermal cameras are used in substations and transformer stations to detect overheating of transformer windings and switchboard edges in real time and to initiate countermeasures in good time. In logistics and warehousing centres, a manageable number of strategically positioned cameras allow large hall areas to be monitored, reducing installation and maintenance costs through lower equipment requirements and less infrastructure. Thermal cameras also provide support in recycling and waste treatment plants by providing early warning of overheated shredders and presses, minimising fire risks and ensuring safe operation.
Mobotix dual-purpose thermal cameras: Technical features and benefits
Mobotix goes one step further and combines early fire detection and classic security monitoring in a single device in its dual-purpose thermal cameras. Thanks to advanced thermoradiometry, these cameras continuously and accurately detect heat radiation, regardless of external lighting conditions.
As soon as a potential hotspot is detected, the system not only triggers an alarm, but also switches to visual recording mode to store colour images and video sequences. This allows not only fire hazards to be documented and analysed, but also security-relevant incidents such as unauthorised access or impending machine defects. The robust design – dust, water and vapour resistant – allows for use in demanding industrial environments, while VdS, EN54 and CNPP certifications ensure that national and international fire protection requirements are met.
In everyday use, users benefit from the dual-purpose functionality through reduced equipment requirements and lower operating costs: a single system handles both machine condition monitoring and classic video surveillance of the production facility. The intelligent software detects thermal anomalies, creates heat maps for long-term analysis and offers interfaces to higher-level control centres or automation systems. This optimises maintenance cycles, automates safety processes and significantly reduces the personnel required for manual checks.
Economic added value and ROI calculation
The financial benefits of thermal early warning systems are measured not only in terms of avoided repair costs and reduced insurance premiums, but also in terms of minimising production downtime and liability risks. Mobotix recommends a simple calculation to estimate the return on investment (ROI): Add up the direct savings from avoided damage, the revenue gained as a result of reduced downtime and any discounts on insurance premiums. Subtract the investment costs for the camera systems and compare the resulting sum with the acquisition costs. Even though intangible factors such as image enhancement, employee safety and environmental responsibility are difficult to express in monetary terms, this equation provides a transparent basis for decision-making. In high-performance industries, even a few hours of unplanned downtime can mean labour costs and lost revenue in the five-figure range – business interruptions that a thermal camera can often prevent entirely thanks to early detection.
Thermal cameras impressively demonstrate how modern sensor technology combines technical excellence with economic efficiency. Regardless of the manufacturer, the following applies: those who make targeted use of their strengths – early hotspot detection, contactless measurement in difficult viewing conditions and versatile application options – while at the same time realistically planning the costs for purchase, calibration and training, can sustainably increase both the operational reliability and cost efficiency of their plant. The Mobotix dual-purpose solution is a prime example of a holistic concept that combines early fire detection, security monitoring and clear ROI calculations in a single device – a model that makes industry and commerce fit for the challenges of today and tomorrow.
