Sensortronic Weighing and Inspection Australia (SWIA) recently completed a significant weighbridge refit for a major industrial site. The site had been experiencing persistent weight-reading inconsistencies and structural concerns that threatened both operational continuity and regulatory compliance. By replacing outdated components with SWIA’s advanced digital load cells and a new weighbridge indicator, the refit has laid the groundwork for a safer, more dependable, and fully legal-for-trade operation. Below is a brief case study of how the project unfolded.
Project Overview
Our team first identified potential long-term issues during routine service visits. The weighbridge frequently shifted off zero—sometimes by as much as 0.40 tonnes—and suffered from damaged end stops and corroded structural elements. On testing the older load cells, two were found to be failing, with internal resistances and output readings well outside manufacturer specifications.
Realising the risk of a critical breakdown that could shut down their entire site, the client opted for a proactive upgrade. Rather than waiting for a major failure, they decided to invest in new components to ensure smooth, continuous operations.
Challenges
- Inconsistent Zero Readings: The previous load cell setup was causing irregular fluctuations in the weighbridge’s base reading.
- Structural Wear: Cracked welds and rusted fixings created unstable load points and compromised weighbridge integrity, safety and precision.
- Compliance Gaps: Without accurate readings, the weighbridge risked failing legal-for-trade requirements and could have led to regulatory penalties.
SWIA’s Solution
Digital Load Cells
Central to the upgrade were SWIA SDWC digital load cells, which measure compression and convert the result directly within the load cell itself. This digital signal is less prone to interference, improving accuracy, reliability, and allowing for benefits such as self-diagnostics and quicker fault detection.
3590EGT8 Weighbridge Indicator
To complement the new load cells, SWIA installed a 3590EGT8 weighbridge indicator. Designed to allow weighbridge operators to manage customer, supplier, product and material databases and capture vehicles transactions via the 8-inch touchscreen display. This indicator also delivers self-diagnosing capabilities when paired with SWIA’s SWDC digital loadcells and integrates seamlessly with modern data management systems like SWIA’s W8suite weighbridge software.
Comprehensive Refit
Before:
- Removed built-up debris beneath and around the weighbridge
- Jackhammered out and replaced worn bottom plates
- Installed new load cell dummies, then reinforced the foundation and grouted-in replacement load cell bearing plates, addressing site-specific conditions to ensure structural integrity
- Fitted the SDWC load cells and ran new wiring for both the load cells and weighbridge indicator
- Recommissioned and verified the upgraded weighbridge and issued the client a 6/B0 conversion certificate to support compliance with legal-for-trade.
With the new system in place, we carried out a full calibration and verification process, aligning with the National Measurement Institute (NMI) Uniform Test Procedures. The weighbridge was then successfully re-verified as a legal-for-trade system, securing compliance for the client.
Results and Benefits
- Improved Accuracy: Eliminated erratic zero readings and safeguarded against drifting weights
- Heightened Reliability: Robust digital load cells and reinforced foundations minimise downtime and prevent critical failures
- Easier Maintenance: Self-diagnostics and durable hardware reduce ongoing service needs
- Regulatory Compliance: The newly verified weighbridge meets all Australian legal requirements for trade use
By opting for an early refit rather than waiting for a complete breakdown, the client ensured uninterrupted operations, enhanced safety, and long-term weighbridge reliability. SWIA’s SDWC digital load cells and 3590EGT8 indicator together form a modern, future-proof weighing solution that keeps pace with demanding industrial environments. This project underscores SWIA’s commitment to delivering cutting-edge, compliant systems that help businesses maintain accuracy, reduce downtime, and protect their bottom line.
For more information about how a SWIA weighbridge upgrade could improve your site, contact our team today.
