Thermal imaging & vision systems I


as they happen and by storing product images and discrete data, giving you full traceability if anything goes wrong.


THE CRITICAL STEP: INNOVATION AND INTEGRATION EXPERTISE


But to be clear, there are challenges in integrating these new technologies. Performance ultimately depends on robust engineering and understanding the environment the technology operates in. Is the product moving or static? What is the material? What is the ambient background? Getting it right means custom integration, testing and calibration.


AI is increasingly used in this instance, and inspection accuracy depends on understanding the size of the training data - with more complexity requiring more images. This is an area of deep learning, a step up from its lightweight cousin edge learning, which instead focuses on quicker deployment of simpler tasks, while deep learning handles more complex situations.


That is why we talk about vision intelligence – not just cameras. It is multimodal with a range of futureproof solutions, all working together to give the system the context it needs to make accurate, meaningful decisions in a fast-moving environment. And of course, let us not forget data-driven insights into production lines. Thermal inspection isn’t about cameras. It is about smarter food production – safer, more consistent, and fully visible. The risk is real, but so is the solution; if you engineer it properly.


Bytronic Vision Intelligence bytronic.com


Instrumentation Monthly November 2025


ADVANCED FURNACE INSPECTION TECHNOLOGY


nfrared thermography has become an indispensable tool in the petrochemical and refining industries, and Jason Czajkowski, IRT Thermography Manager at PROtect, is leading the charge in applying the latest technologies to improve safety, efficiency, and asset integrity. A Level III #13966 certified Master Thermographer and CWI, Czajkowski and his team at PROtect are early adopters of FLIR’s newest furnace inspection tool: the FLIR G609. This article outlines why PROtect transitioned from the trusted GF309 to the advanced G609 and how this upgrade is transforming furnace inspections in high- heat industrial environments.


WHY UPGRADE? THE RESOLUTION ADVANTAGE


For years, the FLIR GF309 was the standard for IR furnace inspections, but it offered only 320 × 240 pixel resolution. Czajkowski recognised the limitations this presented specifically, lower image clarity and reduced ability to spot subtle temperature anomalies at a distance. The FLIR G609, with its 640 × 480 resolution, delivers over four times the pixel count, enabling inspectors to identify small, early-stage issues such as coke buildup or flame impingement that may have gone unnoticed with older technology. In an industry where early detection can mean the difference between a planned repair and a catastrophic failure, resolution matters.


SMARTER TECHNOLOGY IN THE G-SERIES Beyond improved resolution, the G609 brings a suite of advanced features that modernise the inspection process. Its redesigned heat shield mounts with a single screw and provides superior protection during live furnace inspections. The intuitive 4-inch touchscreen interface allows for quick navigation, even with gloved hands. Czajkowski emphasises the value of the 1-Touch Level/Span feature, which automatically adjusts image contrast with a single tap. This allows inspectors to focus on capturing actionable data instead of fumbling with manual settings. Additionally, the G609’s custom furnace lens is calibrated to capture clear thermal images through furnace flames and refractory, something legacy systems struggled with. According to Czajkowski,


Left: Enhanced 640-resolution detector reveals fine thermal details for faster, more accurate inspections. Right: Redesigned cold filter enables clear visibility through flames, even in the harshest conditions.


“It’s not just about seeing through the flame it’s about seeing what matters behind it.”


THE SOFTWARE ADVANTAGE: A TOTAL INSPECTION SOLUTION


Pairing the G609 with FLIR’s Thermal Studio Pro software transforms the camera into a full inspection and reporting solution. PROtect leverages the Route Creator plug-in to plan inspections in advance, assigning inspection points and optimal paths. Once on site, the G609 guides inspectors through this pre-planned route, ensuring no critical component is missed.


Thermal Studio Pro streamlines post-inspection reporting by batch processing images and applying consistent templates. Reports that once took hours to compile can now be generated in minutes, improving turnaround times for clients. “The software enables consistency and speed,” says Czajkowski. “We can now deliver high-quality reports faster than ever before.”


FUTURE-PROOFING AND FIELD LEARNINGS


Czajkowski notes that the G609 isn’t just an improvement in specs it represents a long-term investment in reliability. Its durable design, compatibility with evolving software platforms, and ease of use make it ideal for onboarding new technicians without sacrificing inspection quality. Real-world usage continues to validate its benefits; PROtect has already identified developing issues during inspections that older models would have missed.


CONCLUSION


The FLIR G609 has redefined what’s possible in IR furnace inspections. With Jason Czajkowski’s expertise guiding implementation at PROtect, the new technology delivers unparalleled image quality, user- friendly controls, and efficient software integration. As the refining and petrochemical industries demand ever-higher standards of safety and uptime, PROtect’s forward-thinking approach ensures its clients stay ahead of the curve.


Side-by-side comparison of FLIR GF309 (left) and FLIR G609 (right)


FLIR www.teledyneflir.com 31


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73