Precision Weighing for Reliable Manufacturing
Accurate process weighing is essential in modern manufacturing, where even small measurement errors can lead to material waste, inconsistent product quality and an overall increase in production costs.
Typical process weighing applications include batch weighing systems, tank and silo weighing, conveyor / belt scales, check weighers and loss-in-weight feeders.
Novatech Measurements have worked with numerous industrial manufacturers to deliver bespoke weighing solutions that improve process control and production efficiency across all types of process weighing.
Batch Weighing
Batch weighing applications typically involve a real time measurement of quantity, by weight, of one or more individual ingredients or components that are being added sequentially to a vessel.
Accurate measurement is required to ensure a consistent balance between the various component parts to maintain the quality of the end product. Repeatable measurement devices with good return to zero characteristics are vital to ensure that the process can be repeated in an identical manner and cycled as quickly as possible.
Long term stability and reliability are also important as any down time on such systems tends to lead to a significant loss of production and income.
The Challenge
One of our customers required a reliable weighing system that could monitor the relative quantities of two materials being supplied into a tipper via individual chutes connected to shakers.
These shakers would move the components down the chute at a controlled speed but would cause vibrations throughout the rest of the assembly. Their existing equipment produced inconsistent readings due to vibration and uneven loading and would often fail after a short time due to the demanding operating environment.
Any repair or replacement required a large assembly to be decommissioned and decontaminated so the part could be removed, leading to extraordinary down time.
The key objectives were to:
- Improve weighing accuracy and repeatability.
- Reduce material waste.
- Integrate with the existing PLC control system.
- Minimise maintenance and production downtime.
- Provide a long-term, reliable weighing solution.
The Solution
Novatech supplied a bespoke process weighing system using precision strain gauge load cells designed specifically for industrial process applications. The load cells were selected to provide exceptional accuracy, long-term stability, and reliable performance under continuous operation.
Working closely with the customer, our engineering team ensured the system integrated seamlessly into the existing process control infrastructure while maintaining high measurement accuracy throughout the operating range.
Key Features
- High-accuracy strain gauge load cells
- Robust stainless steel construction
- Excellent repeatability and long-term stability
- Suitable for continuous industrial operation under high frequency vibration
- Easy integration with PLC and automation systems
- UK-manufactured and fully traceable calibration
The Results
Following installation, the customer experienced significant operational improvements:
- Improved process control through accurate real-time weight measurement.
- Reduced raw material waste and product giveaway.
- Increased production consistency between batches.
- Improved overall product quality.
- Reduced maintenance requirements.
- Greater confidence in process monitoring and quality assurance.
The new weighing system enabled operators to respond quickly to process changes, improving efficiency and reducing costly production interruptions.
Checkweighers
Checkweighers are used on production lines to automate a process involving items that need to be checked for weight and/or other parameters as they pass a particular station, leading to an automated rejection process for any non-compliant items.
These are particularly common in the food industry and load cells for this purpose are often required to withstand harsh environments. Quite often they will be hosed down with pressure washers using various chemicals that are necessary to keep equipment sterile.
The Challenge
One of our customers needed to use a pair load cells connected to rollers that would sit either side of a conveyor and impart a force from both sides to liquid filled plastic bottles as they passed by at speed.
If the load cells measured the expected force, this was a sign that the cap on the bottle was correctly fitted, as the pressure inside the bottle would increase.
A low measurement would suggest that the cap was not correctly fitted as the air could escape and this would need to activate an automated rejection of the non-compliant item.
The key objectives were to:
- Provide rapid measurement response via a device fitted with relay switches
- Automate a rejection function via a moveable arm that could operate faster than the speed at which the bottles were being conveyed
- Ensure that the load cells could withstand continuous splashing from the liquid where caps were not correctly fitted and allow for cleaning with harsh chemicals
The Solution
Novatech supplied load cells and instrumentation capable of rapid response to repeat measurements and extremely quick actuation of relay controlled set-points to implement a pass-fail control mechanism.
The sensors integrated seamlessly with existing equipment and allowed the process to continue at a higher speed than before.
Loss-in-Weight Feeders
These are typically associated with dosing systems that would measure the decreasing weight of material as it is dispensed from a vessel into some other part of the production process.
In this sense, they are similar to batch weighing applications, but the point of measurement is at a different stage of the process.
Loss-in-weight measurement can be used to accurately control feed rates and provide operators with advanced warning of a component reaching low levels and needing refilling.
Novatech have been involved in a wide range of dosing applications, from pharmaceuticals to additive manufacturing / 3D printing. Our consistent approach to design and commitment to quality ensure that we provide measurement solutions that can improve the repeatability of production processes and minimise costly waste in terms of both time and materials.
Why Choose Novatech?
For over 50 years, Novatech Load cells has designed and manufactured precision force measurement solutions for customers across a wide range of industries.
Every load cell is engineered for accuracy, reliability, and long service life, with bespoke solutions available to meet the most demanding applications.
Whether your application involves vessel weighing, hopper weighing, batching, mixing, or automated production processes, our experienced engineering team can develop a solution tailored to your exact requirements.
Ready to Improve Your Process Weighing?
If you’re looking to increase weighing accuracy, reduce waste, and improve production efficiency, contact Novatech Load cells to discuss your application.
Our engineers are ready to help you find the right solution for your process.