Customer Challenge

• Low manual weighing efficiency, long vehicle queues, and severe congestion during peak hours.
• Manual loading depended on operator experience, leading to overloading or short loading, high material loss, and rework costs.
• Corrosive chemical materials damaged ordinary carbon steel platforms and sensors, causing frequent maintenance.
• Some areas were explosion-proof zones, creating safety hazards for traditional electronic equipment.
• Weighing data was recorded on paper, could not be uploaded in real time, and was difficult to trace and audit.
• There was a risk of data tampering and vehicle substitution fraud.
• The system could not integrate with the existing ERP, WMS, and environmental supervision platforms, forming information silos.

Our Solution

Xuzhou Spear Weighing Equipment Co., Ltd. designed a complete chemical intelligent weighing and quantitative loading system based on the site conditions. The main components included:

• Explosion-proof digital electronic truck scale: IP68 digital load cells, stainless steel platform, and anti-corrosion coating for corrosive environments; intrinsically safe indicators and junction boxes for explosion-proof areas.
• Automatic quantitative loading system: PLC-controlled valves, pumps, and flow meters combined with real-time weight feedback from the truck scale to achieve automatic quantitative loading; automatic stop upon reaching the preset weight to reduce overloading and spillage.
• IoT smart card weighing system: Drivers use RFID/IC cards for self-service check-in; the system automatically identifies vehicles, controls barrier gates, provides LED guidance and voice prompts, and enables unattended weighing.
• Video monitoring and anti-cheating: License plate recognition, snapshot comparison, and infrared beam sensors to prevent incomplete weighing, repeated weighing, and other fraudulent practices.
• Data management platform: Real-time cloud upload of weighing data, automatic report generation, and interfaces for ERP, WMS, and environmental supervision platforms.
• Safety and alarms: Overload alarms, overflow prevention alarms, electrostatic grounding detection, and emergency stop buttons to ensure chemical loading safety.

Results

• Improved measurement accuracy: Loading error reduced from ±0.5% to within ±0.1%, reducing material loss and trade disputes.
• Significantly higher efficiency: Loading time per truck shortened by about 35%–40%, and vehicle queuing congestion noticeably relieved.
• Lower labor costs: Unattended weighing and loading reduced 2–3 operators per shift.
• Stronger anti-cheating capability: Triple verification by card, license plate, and video, with automatic data upload, greatly reducing the risk of manual tampering.
• Longer equipment life: Anti-corrosion stainless steel platform and IP68 sensors adapted to the chemical environment, extending maintenance intervals and reducing annual maintenance costs by about 30%.
• Traceable data: All weighing records, loading data, and video snapshots are automatically archived to meet audit and environmental supervision requirements.
• System integration: Seamless integration with the client’s ERP and WMS for unified order, inventory, weighing, and settlement management.

Testimonial

“The intelligent weighing and quantitative loading system provided by Xuzhou Spear Weighing Equipment Co., Ltd. completely solved our problems of inaccurate chemical weighing, low loading efficiency, and opaque data. The system runs stably, and the explosion-proof and anti-corrosion design fully meets our on-site safety requirements. Now drivers can complete weighing by self-service card swipe, and data is uploaded to the management platform in real time. Our operational efficiency and compliance level have both improved significantly.”

— Head of Equipment Management Department, the chemical enterprise