Blackline Safety

Improving Industrial Safety with a Modernized Data Platform and Analytics on AWS

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Transforming Industrial Safety with IoT & Data Analytics on AWS

Blackline Safety is a global connected safety leader, providing wearable safety technology, personal and area gas monitoring, cloud-connected software and data analytics. Since the launch of its first G7 cloud-connected safety wearables in 2016, Blackline Safety has experienced rapid growth — expanding into new markets and growing its employee count from 80 to more than 260. As its user base expands, Blackline delivers services to an increased number of customers who seek to leverage data across all aspects of their organizations. This growth has driven the creation of the Blackline Vision data science team as well as a suite of services that assist businesses with getting the most from their digital transformations.


Industrial Safety, Technology


Implement a high volume data streaming and processing infrastructure on AWS to support an expanding customer base and growing solutions portfolio. Support the requirements for a contact tracing reporting solution to keep workers safe amidst the COVID-19 pandemic.

Services & Tech

AWS, Amazon S3, Amazon Redshift, AWS Lambda, Amazon Kinesis, Amazon EMR and Delta Lake

The Challenge

With an ever-expanding customer base and portfolio of solutions, Blackline Safety now manages more data than ever before, which needs to be processed in real-time to provide customers with insightful analytics about their business. As a result of this rapid growth, Blackline’s Software Development and Blackline Vision teams recognized that limitations of their current architecture may arise if not addressed. The teams needed assistance with Amazon Web Services (AWS) platform expansion to efficiently process data from a growing number of products in the field combined with a planned increase of data reported from each connected wearable. 

Compounding Blackline’s challenge of managing a growing stream of data from connected wearables, 2020’s COVID-19 pandemic introduced new urgency for the project. Early in the year, Blackline collected client interest regarding their need for industrial contact tracing support. While Google and Apple announced their collaboration efforts to support a comprehensive smartphone platform, these consumer devices were not certified intrinsically safe and could not be taken into refineries, power plants and many other industrial facilities. To keep employees safe and healthy in an office or out in the plant, Blackline leveraged its intrinsically safe employee wearables, cloud-hosted software and data analytics to provide automated reporting and visualizations to support contact tracing investigations in the industrial workplace.

“At Blackline’s stage of accelerating growth, it was becoming difficult to balance critical software innovation with the need to grow our team and simultaneously manage improvements to our platform,” said John Moura, Director, Software Development and Operations. “We knew that investing into our cloud infrastructure would support our next phase of growth, but it was critical to select the right partner with deep experience and a proven track record — we found that partner with Onica.”

Blackline realized they needed a partner with big data expertise that could help re-architect some elements of their current platform. Further, they required additional resources to build out a data lake architecture to support new industrial contact tracing reporting — a proprietary solution that required rapid development for a quick deployment to help keep workers around the world safe and healthy amidst the global COVID-19 pandemic. 

A key challenge of the project was discovering how to support the planned increase in data flowing in from Blackline connected wearables in the field. To better support clients’ growing needs, including industrial contact tracing, the data rate from each wearable was required to shift from once every five minutes (when not in alarm), to once every ten seconds — an increase by a factor of 30x. 

The Solution

Blackline engaged with Onica, a leading AWS Partner Network (APN) Premier Consulting Partner excelling in leveraging cloud capabilities to optimize business’ efficiency and output. Supporting Blackline’s existing AWS infrastructure, the Onica team worked with Blackline to implement a solution, using Amazon Kinesis and Amazon EMR, to collect high volume data streamed from G7 devices in the field via integrated cellular and satellite connectivity. 

The result is a workflow to ingest the higher data rate raw messages and then enrich them to deliver high-value data in Amazon Redshift for reporting. It also integrated Delta Lake, providing scalable handling and cohesive streaming of data. 

With this new infrastructure, data is ingested and routed using a number of tools in order to preserve its integrity. It is then enriched, transmitted and assembled depending on its application, including: contact tracing reporting, mapping of gas leaks, viewing equipment usage, visualizing alert types and assessing equipment testing and calibration compliance. 

During the project, Onica also provided assistance with setting up AWS load balancers and resolved some constraints with AWS partners through online technical troubleshooting sessions. 

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“With the world’s response to COVID-19, the need for industrial contact tracing technology to support return to work initiatives has never been greater. With the help of Onica, Blackline will be able to increase the quality of insights that we deliver to clients through data science and a growing suite of analytics tools.”
Lohrasp Seify
Business Lead for Blackline Vision

The Outcome

To unlock the potential for more advanced data analysis with the benefit of more granular data, and to address the growing demands of its clients, Blackline’s previous architecture needed to evolve. Onica successfully assisted Blackline migrate from its conventional data ingestion and database storage to a contemporary AWS infrastructure that will support their future growth and innovation.

The results of the Onica and Blackline collaboration had the immediate impact of enabling the deployment of higher data rate reporting from their connected wearables, helping their clients to make more informed decisions about their businesses.

“With the world’s response to COVID-19, the need for industrial contact tracing technology to support return to work initiatives has never been greater,” said Lohrasp Seify, Business Lead for Blackline Vision. “With the help of Onica, Blackline will be able to increase the quality of insights that we deliver to clients through data science and a growing suite of analytics tools.”

An additional achievement of the partnership was support for the launch of the Blackline Vision team’s highly visual and interactive industrial contact tracing infrastructure to help industrial companies respond to the COVID-19 pandemic. This included reports that display maps and other visuals that highlight close interactions between employees over designated periods of time, using data collected by their G7 wearable devices. The teams successfully ensured information is strictly maintained for each client organization, only providing access to designated users through strict user access controls.

“Onica is a valued partner of Blackline Safety — they have helped us navigate various challenges and prepare us for the future,” said Mr. Moura. “With Onica onboard, we knew we had the support of infrastructure experts who understood our challenges and could help us build a solution to meet our immediate and future needs, supporting our rapid growth.” 

Why Us

Why Onica

Onica is one of the largest and fastest-growing Amazon Web Services (AWS) Premier Consulting Partners in the world, helping companies enable, operate, and innovate in the cloud. From migration strategy to operational excellence and immersive transformation, Onica is a full spectrum AWS integrator. Learn more at