Industrial Network & Security Infrastructure for Adi Sakthi Fabricators — Manufacturing Facility, Tamilnadu | Layerix Networks
Client: Adi Sakthi Fabricators
Technologies Deployed
About Adi Sakthi Fabricators
Adi Sakthi Fabricators is a manufacturing enterprise based in Tamilnadu, specialising in industrial fabrication and precision engineering. With a focus on quality and timely delivery, the company serves clients across automotive, infrastructure, and heavy engineering sectors.
The manufacturing facility operates round‑the‑clock shifts, housing heavy machinery, raw material storage, finished goods inventory, and administrative offices. As production scaled up, the need for a reliable, secure, and auditable network and surveillance infrastructure became critical — to monitor operations, prevent theft, and enable seamless communication between production and management teams.
Layerix Networks was engaged to design and deploy the complete physical and security layer — from structured cabling to WiFi to CCTV — using industry‑leading components from Commscope and Dahua, with professional rack integration and full documentation.
The Challenge — Securing a Live Manufacturing Facility
The Adi Sakthi Fabricators facility faced several challenges common to industrial environments:
- Unreliable legacy network: Existing cabling was ad‑hoc, causing intermittent connectivity for production terminals and inventory systems.
- Security blind spots: No CCTV coverage in key areas — material storage, loading docks, and perimeter — leading to risk of theft and operational disputes.
- No WiFi for mobile workflows: Supervisors and quality inspectors relied on paper logs, delaying data entry and decision‑making.
- Harsh environment: Dust, vibration, and temperature variations demanded rugged cabling, industrial‑grade components, and professional installation.
Layerix Networks proposed a complete overhaul — structured cabling with Commscope Cat6, a Dahua‑based surveillance system with 32‑channel NVR, managed switches, and WiFi access points — installed with zero disruption to ongoing production.
The Scope — From Cables to Cameras to Connectivity
Layerix Networks delivered a turnkey infrastructure solution covering:
Structured Cabling (Commscope Cat6)
End‑to‑end Cat6 cabling using genuine Commscope cables, keystone connectors, patch panels, face plates, and RJ45 clips. 1‑inch PVC conduits with bends, tees, and joints used throughout. Professional labelling on both ends for easy identification.
Surveillance System (Dahua)
Dahua 2MP outdoor cameras (model DH-IPC-HFW1230TL2-A) installed at key points — production floor, storage, entry/exit, and perimeter. Connected to a Dahua 32‑channel NVR with a 6TB WD hard disk, providing 30+ days of continuous recording.
Network Racks & Enclosures
Two Netrack racks installed — 6U for distribution and 9U for main equipment. 4×4 inch backboxes used for CCTV junction points, ensuring neat and secure terminations.
Enterprise Switches
Managed switches deployed to segment traffic between production, admin, and surveillance VLANs — ensuring non‑blocking performance and remote manageability.
Industrial WiFi
Access points positioned for blanket coverage across the facility — enabling real‑time inventory updates, digital work orders, and supervisor mobility.
Installation & Documentation
Full installation charges included — cable pulling, termination, rack assembly, camera mounting, NVR configuration, and switch programming. Complete as‑built drawings and test reports delivered.
Every component was sourced from authorised distributors: Commscope patch cords, Cat6 cable, keystones, and face plates; Dahua cameras and NVR; WD hard disk; and Netrack racks. All consumables (insulation tape, cable ties) were included.
Multi‑Phase Delivery
Laying the Foundation – Commscope Cat6 Infrastructure
Phase 1 focused on replacing the legacy cabling with a professional, certified structured cabling system. Layerix engineers surveyed the facility, planned cable runs through 1‑inch PVC conduits, and installed Netrack racks (6U and 9U) in the main equipment room.
Cable Pathways
1‑inch PVC pipes with bends, tees, and joints routed overhead and through walls — protecting Cat6 cables from dust, heat, and mechanical damage.
Commscope Components
24‑port loaded patch panels, keystone connectors, face plates, and RJ45 clips — all genuine Commscope, ensuring gigabit performance and warranty.
Rack Installation
Netrack 6U and 9U racks securely mounted, with cable management bars and grounding. Equipment layout planned for future expansion.
Professional Labelling
Every cable end, patch panel port, and face plate labelled with a consistent scheme — reducing troubleshooting time by 80%.
24×7 Security with Dahua Cameras + NVR
Phase 2 brought security and wireless connectivity. Layerix deployed Dahua 2MP outdoor cameras at strategic locations, installed the 32‑channel NVR with 6TB storage, and rolled out enterprise WiFi access points.
Dahua Camera Installation
DH-IPC-HFW1230TL2-A cameras mounted on walls/poles using 4×4 inch backboxes. Each camera connected via dedicated Cat6 drops to the NVR, with power over Ethernet (PoE) from the switches.
NVR & Storage
Dahua 32CH NVR loaded with a WD 6TB hard disk — configured for continuous recording, motion detection alerts, and remote access for management.
WiFi Access Points
Industrial‑rated APs positioned for coverage in production hall, warehouse, and offices — enabling mobile devices, tablets, and handheld scanners.
Switches & VLANs
Managed switches configured with separate VLANs for CCTV (isolated from internet), production network, and guest WiFi — enhancing security and performance.
Final Commissioning, Training & Documentation
The final phase included programming of managed switches, end‑to‑end testing, user training, and delivery of complete documentation.
Switch Programming
QoS policies for VoIP (if needed), port security, loop prevention, and SNMP monitoring enabled. Remote management access configured for Layerix support.
System Testing
Cable certification (Fluke test), camera focus and coverage validation, WiFi speed and roaming tests, and NVR playback verification.
User Training
On‑site session for facility manager: NVR playback, camera adjustments, WiFi access procedures, and basic switch troubleshooting.
Documentation Package
As‑built cabling diagram, IP address scheme, device credentials, warranty certificates for Commscope/Dahua/WD, and test reports.
The Customer Win — A Future‑Ready Factory Floor
Adi Sakthi Fabricators now operates with:
- Reliable connectivity: Commscope Cat6 structured cabling eliminates network dropouts, ensuring production terminals stay online.
- Complete security visibility: Dahua cameras covering every critical zone, with 30+ days of footage stored on the 6TB NVR.
- Mobile workforce enablement: Facility‑wide WiFi allows supervisors to update inventory in real time, reducing data entry lag.
- Professional documentation: Labelled cables and as‑built diagrams mean any future changes or troubleshooting are straightforward.
“Layerix delivered exactly what they promised — a complete, documented, and reliable network and security system, without stopping our production for a single shift. The choice of Commscope and Dahua gives us confidence in long‑term performance.”
— Facility Manager, Adi Sakthi Fabricators
Components & Technologies Deployed
Project Scale
30+ (production + admin)
Dahua 2MP (multiple outdoor)
32‑channel, 6TB storage
Zero production downtime
Why Structured Cabling & Surveillance Are Critical in Manufacturing
In a fabrication unit, network downtime means halted production, delayed shipments, and safety risks. Surveillance gaps invite theft, disputes, and compliance failures. Layerix’s approach uses certified components (Commscope for copper, Dahua for video) and professional installation practices (labelling, conduit protection, rack mounting) to ensure long‑term reliability in harsh industrial conditions.
For Adi Sakthi Fabricators, this investment translates to higher operational efficiency, lower risk, and a foundation for future Industry 4.0 initiatives (e.g., machine monitoring, predictive maintenance).
“A factory’s network is as important as its power supply. We build both to last.”
— Layerix Networks Engineering Team
About Layerix Networks
Layerix Networks is a Bengaluru‑based enterprise technology company with 28 certified engineers and a zero‑subcontractor policy. We design, deploy, and manage complete digital infrastructure for manufacturing, commercial, and pharmaceutical clients — including structured cabling (Fluke‑certified), surveillance (Dahua/Hikvision), enterprise networking, WiFi, access control, and managed services. Every deployment is documented, warrantied, and built for industrial resilience.
Key Results
Commscope Cat6 cabling across production and admin areas
Dahua 2MP outdoor cameras with 32CH NVR and 6TB storage
Enterprise switches (managed) for reliable connectivity
Industrial‑grade WiFi access points
Professional labelling, rack installation, and full documentation
Zero downtime during deployment
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