How a Swiss Waste-To-Energy plant is eliminating unplanned shutdowns using Jaipur Robotics AI
At the ACR Waste-To-Energy plant in Giubiasco, Switzerland, unplanned shutdowns were more than just an inconvenience, they were a costly and disruptive challenge. On average, the plant faced four shutdowns per year, each of which was often caused by unexpected materials in the waste bunker. Items such as gas cylinders, tires, and oversized metal pipes would frequently bring operations to stop, causing significant equipment risk and economic losses due to downtime in energy generation.
“Each time the plant shut down, the safety risk increased. It was a serious operational concern.” — Plant Manager, ACR Giubiasco
These recurring shutdowns aren’t just technical glitches, they carry serious consequences for both the team and the plant’s bottom line. Each incident results in hours of lost productivity, with downtimes ranging from 8 hours to several days, and requires urgent maintenance interventions. One of the most pressing issues across Europe is the growing presence of hazardous materials, such as gas canisters and batteries, which pose significant safety risks, often leading to explosions and fires.
To tackle this challenge, ACR adopted Jaipur Robotics’ AI-powered monitoring system, specifically designed for waste bunker environments. The solution integrates advanced vision technology with continuous learning capabilities, enabling operators to identify and address issues before they escalate. At the Giubiasco plant, a Sensor Box was installed above the waste bunker, delivering real-time detection of critical waste items. Powered by Jaipur’s proprietary AI models, the system automatically identifies and flags problematic objects for operator review through a dedicated touchscreen dashboard.
“It feels like we now have an extra set of eyes. The app is very easy to use and integrates smoothly into our workflow”— Operator, ACR Giubiasco
Operational reliability and measurable efficiency
In just five months, ACR saw a remarkable transformation thanks to Jaipur Robotics’ AI-powered monitoring solution. Since its installation, the plant has experienced zero shutdowns, meaning no costly interruptions. The system has been running with 100% uptime, providing continuous monitoring of the bunker area.
Over X,XXX problematic waste items have been detected and accurately classified according to the plant’s criteria (across more than 50 categories, with classification accuracy nearing 100%). These include:
- Hard and Oversized waste
- Non-compliant materials
- Dangerous waste
- Metal rods and pipes
- Tyres
“This system changed our daily operations. It’s not just a tool—it’s a preventive approach to plant safety and efficiency.” — Technical Director, ACR Giubiasco
ACR’s experience showcases the tangible benefits of AI-driven waste monitoring: improved safety, streamlined operations, and uninterrupted performance. Jaipur Robotics delivers measurable results by combining innovative technology with close collaboration, continuous improvement, and a commitment to solving real-world challenges.
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