What's Involved In A Truck Scale Installation?

What’S Included in a truck scale installation?

So you picked out your new truck scale and are ready to start weighing trucks. However, before any weighing can start, your new truck scale needs to be installed. Installation of a truck scale includes a number of different components that your local scale dealer will complete. The main areas of the installation include setting the scale, anchoring the scale, running all cabling, wiring the scale, setting up peripheral devices, calibrating the scale, and placing the scale into service. Below we will review each area:

1. Setting The Scale:

Prior to setting the scale your foundation will be complete. To learn more about truck scale foundations check out this blog post. Setting the scale involves using a crane, loader, or other lifting equipment to offload the truck delivering the scale and placing the scale modules onto the foundation. Setting the scale can be a lengthy or short process depending on whether there is easy access to the foundation. For example, setting a scale on a foundation located in an open field is a quick & easy process; however, setting a scale inside the tunnel of a feed mill facility is much more difficult due to height restrictions. Your scale company will also be the ones to arrange the logistics of the truck and crane. Once the truck scale is set on the foundation, it’s time to begin anchoring.

2. Anchoring The Scale:

After the scale modules are set on the foundation they will require adjustments to ensure they are aligned properly. Large breaker bars and interconnect bolts will help ensure the modules are in the correct location. Once the scale is in the correct location it will be set onto the base plates and load cells. At this point, the scale technician will begin drilling anchor bolt holes in the foundation and then installing and tightening the anchor bolts. At the end of anchoring, the scale should be secured to the new foundation and centered + level with the approaches & end-walls. Also any checking or adjustment bolts will be installed and set to the correct tolerances.

3. Wiring The Scale:

Depending on what brand and type scale you purchased, the wiring of the scale will be different for each. For most electronic truck scales, each loadcell’s cable requires running it to the junction box. Here, each loadcell cable will be landed on the internal board. The color coding for the wires on loadcells varies dramatically between different manufacturers, this is where a trained scale technician comes in. The final step is attaching the homerun cable to the junction box and running it to where your scale indicator will be located. At this point your truck scale is on the foundation, anchored, and wired to your scale indicator.

4. Setting Up Peripheral Devices:

In addition to the truck scale a number of other devices are normally connected to the scale indicator. Most states require legal-for-trade truck scales to have a remote display or scoreboard, to learn more about the requirements checkout this blog post. The scale technician will wire the indicator and program it to send the weight data to the remote display so the truck driver can see his weight while on the scale. Printers are another common peripheral device. Connecting the printer involves wiring the scale indicator to the printer and setting up a number of parameters to ensure the scale ticket prints correctly. Other peripheral devices can include outputs to HMI / PLCs, photo-eyes, etc.

5. Calibrating The Scale:

This step of the installation process involves calibrating your new truck scale to ensure it is weighing correctly. Your scale company will bring a heavy-capacity test truck on-site to use for this task. Known weights such as 20,000 lbs will be placed over each load cell and section during the calibration procedure. At the end of the calibration your truck scale will be weighing accurately. You will also receive a truck scale test report from your scale company outlining the results of the calibration.

6. Placed Into Service:

The final step that is required is if your truck scale is being used in a legal-for-trade operation then it will need to be placed into service with your state. This step is completed by your scale company and ensures you are legally allowed to start using your new truck scale.

As you can see, the process to install a truck scale has numerous steps and can range from simple to complex. To learn more about the cost of a truck scale, checkout this blog post.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

A Guide To Selecting A Wash Down Scale

A Guide to selecting a wash down bench scale

Scales are used almost everywhere, sometimes in austere conditions or in demanding environments. Washdown scales are designed and built to withstand wet environments and harsh industrial conditions. As the name indicates, these scales have easy cleaning access after use and are constructed to prevent liquids and particles from penetrating internal scale components. Washdown scales are found in various industries and applications.

What does it mean for a scale to be “washdown”?

Washdown DOES NOT EQUAL waterproof.  Different scales and electronic components have different protection ratings; these ratings for washdown scales can vary by make and model. Ingress Protection, or IP ratings, highlights the protection rating from elements like water and dust as well as cleaning chemicals. Scales with low IP ratings can generally resist spills or humid environments while scales with higher IP ratings can be washed with heat and pressure.

Types of washdown scales

Washdown scales are generally made of stainless steel and they come in a range of shapes and sizes.

 -          Bench scales
Washdown bench scales tend to be small to medium -sized. These scales can have capacities around 300 lb and lighter; the readability, or division size, is dependent on the scale capacity. Washdown bench scales are useful in food and beverage, pharmaceutical, specialty chemical and several other industries. The scales are often found in warehouses, laboratories and commercial environments. To see different models of bench scales click here.

 -          Floor scales
Washdown floor scales are larger than bench scales, usually 3 by 3 and larger. They are durable and handle heavy loads up to 10,000 lb. Washdown food scales are often used in food processing areas, commercial warehouses and dockyards for weighing items in bulk. To see different models of floor scales click here.

 -          Tank scales
Stainless steel weigh modules and load cell systems can be installed under tank legs for weighing bulk quantities in docks or in food processing facilities. They're built to withstand demanding conditions in harsh environments with sealed components that are protected from water and dust ingress. Tank scales are built with checking to handle stresses from agitators and motors.

 -          Retail scales
Washdown retail scales are compact and legal for trade. They offer all the usual functions of approved scales, such as a display that shows weight, price per unit and total cost, a rear-mounted display that customers can see, and portability for convenience.

Which industries use washdown scales?

The food and beverage industry has high standards for hygiene as well as frequent audits. In order to produce the best possible product in sanitary environments, food producers always use washdown scales in production areas as well as other wet areas. The medical and pharmaceutical industries also use washdown scales to maintain clean and sterile conditions.  Retail stores that sell food use washdown scales to clean between customers or to avoid cross contamination. Manufacturing facilities, logistics warehouses and construction sites with significant dust and debris use washdown scales given the austere conditions.

Load cell system: electronic versus hydraulic

One of the most important considerations when purchasing a wash down scale is what type of load cell system to get. The two primary washdown scale types have either electronic load cell systems or hydraulic load cell systems.

Electronic load cell system: electronic scales work based on simple strain gauge circuits. These strain gauges are installed inside the load cell body. The load cell connects to the summing card or digital weigh indicator via four conductor or six conductor wire. Components in this system include:

o   Load cell(s)
o   Electronic cables
o   Junction box
o   Summing card (PCB)
o   Digital weight indicator

Hydraulic load cell system: hydraulic scales work based on hydrostatic pressure. There are no electrical components under the scale. The load cells are connected to a hydrostatic totalizer via stainless steel tubing. The system is pumped with hydraulic fluid and the totalizer converts the pressure to weight via a single strain gauge load cell. Components in the system include:

o   Load cell(s)
o   Stainless steel tubing
o   Hydrostatic totalizer
o   Digital weight indicator

In nearly all washdown applications, hydraulic scales are far superior to electronic scales. For starters, the hydraulic scales are completely immune to water damage. To learn more about hydraulic load cells checkout this blog post.

 Summary

Washdown scales are great for a variety of reasons – they are built to work in challenging conditions and environments. Their design both improves and speeds up cleaning, keeping the scale reliable. Great clean-up prevents material build up, cross contamination, and growth from mold or bacteria. The IP rating is key to knowing exactly how protected the washdown scale is from water and dust. The folks at American Scale have seen these scales in hundreds of different environments. We’ve seen what works as well as what doesn’t – we are here to help you make decisions regarding your next washdown scale.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

How To Choose A Bench Scale

How to choose a bench scale?

Bench scales are widely used across industries in a broad range of applications. They are usually packed with useful features and functions to optimize the weighing experience. Bench scales have a compact footprint, often they are small enough to fit on counters, workstations, carts, and tables. Common places you’ll see a bench scale include kitchens, veterinary offices, retail shops, grocery stores, or industrial settings. To learn more about bench scale basics checkout this blog post.

What is a bench scale?

A bench scale is designed to be placed on a table or counter during weighing. They have large platters or weighing pans and they take up a small footprint. Many bench scales come with an integrated indicator and keypad while others have a detachable indicator that is usually mounted on a column or a nearby wall. Bench scales are designed to weigh a broad range of products. In general, they are affordable and easy-to-use. They provide the features and precision needed for most businesses, offering a professional weighing solution to those on limited budgets. There are so many different manufacturers out there you can find a variety of capacity, readability, and platform size options.

Examples include:

Bench Scales Applications

The most frequently used applications for bench scales include checkweighing and counting. Bench scales are ideal in assembly or manufacturing shops; the scales weigh raw materials, count pieces before packaging, or checkweighing during quality control. Bench scales of varying capacities can be used in shipping and receiving operations. These scales weigh boxes, ensuring fair and accurate transportation costs. The scales fit on counter-tops and easily communicate with computers and printers. Bench scales can also be used in production processes, to weigh ingredients when making small batches of things like food, soaps, and candles. Grocery stores, cafeterias, and other retail shops use bench scales to weigh foods, candy, and ice cream.

Available Features

To ensure easy cleaning, look for a bench scale with a stainless steel platform and sealed keypad. Overload protection ensures the scale isn’t compromised by excessive weight, and can help it last longer. When used in quality control, checkweighing scales allow users to set weight limits and visually see whether the scale is weighing over or under the limit. Some scales have audible alarms, in addition to the visual alarm.

 Bench scales can also include a rechargeable battery in addition to an AC adaptor. The rechargeable battery provides power to the scale and allows users to move the scales around or use them in places where electricity isn’t easily accessible. It is important to know how long the battery can operate without being recharged when spec’ing out the scale. Other options include a backlight to aid in visibility and/or automatic power-off features to save on power consumption and increase life.

 Ease of connectivity is also an important consideration for some bench scale uses. For the most part, bench scales are easy to integrate into other software systems (like a shipping operation). The scale should come with an RS-232 and/or USB interface to connect to computers, printers, and other peripheral devices. The digital weight indicator can also be programmed to follow a specific workflow and capture variable data entered by the user. This database can then be saved locally on the scale or the data can be shared across a network.

One of the most important considerations is to make sure and check that the capacity and readability suits your requirements. This, along with other features and functions (such as checkweighing, parts counting, etc) are important points that must be considered prior to purchase. If you need help finding the right bench scale, or you simply want to learn more, you can contact us.

Learn more about the bench scales that American Scale Offers here

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Functions of Analytical and Precision Balances

Analytical Balance: What Are the Uses?

Most people have never had the requirement to use more than the basic weighing function of a scale. However, many weighing balances are capable of much more advanced functions which can simplify a variety of complicated tasks. This article  presents an informative summary of some of the main functions of weighing balances, enabling you to get the most out of your weighing balance.

What is a Weighing Balance?

A weighing balance is an instrument that is used to determine the weight or mass of an object. It is available in a wide range of sizes with multiple weighing capacities and is an essential tool in laboratories, commercial kitchens and pharmacies. To learn more checkout this blog post.

What is the difference between a Precision and Analytical Balance?

Precision and analytical balances are specific types of weighing balances which measure much smaller masses than the average scale. An analytical balance is the most precise because it has a higher readability, measuring to the nearest 0.0001g. Analytical balances usually include draught proof weighing chambers for precise measuring of mass and are often used alongside anti-vibration tables to increase accuracy. A precision balance on the other hand typically measures to the nearest 0.1-0.01g but has higher capacity. Both can measure capacities from hundreds of grams to kilograms.

What are the Main Weighing Balance Uses?

Balances are generally more sophisticated and precise than scales and are therefore commonly used by professionals for advanced scientific weighing in the following industries:

-          Pharmaceutical
-          Educational
-          Food and beverage
-          Chemical
-          Industrial 

Due to their high precision and advanced technology, precision and analytical balances are used in laboratories to efficiently perform specific tasks such as weighing test materials and sampling amounts, formulation, density determination, purity analysis, quality control testing and material and conformance testing. These analytical balance functions will be explained in detail in this article.  Balances with higher capacities are not only used in laboratories but can be used to test larger high-capacity weighing materials such as in construction sites.

Function : Formulation
Description: Formulation (AKA recipe calculation) is a selectable weighing mode that is available on more advanced precision and analytical balances. Formulation enables the user to store, add and calculate the weights of multiple ingredients, providing a total weight value. Formulations must be repeatable, so it is critical to accurately weigh each ingredient or component and ensure the proper ratio of each within the formulation. Many semi-micro, analytical and precision balances offer both simple formulation and database formulation, which can be used to store custom formulae and recipes, making it easy to recreate a formulation. Formulation can be used in a wide variety of weighing balance applications, including in pharmaceutical labs, research and development labs, new product development, food production, beer brewing, paint mixing and even mixing ink for screen printing.

Function: Density Determination
Description: The accurate determination of the density of a substance is a critical part of the research process in sample analysis. Density is also an important parameter in quality control, as variations in the density of a solid for example can indicate air pockets that could jeopardize the integrity of the material. Similarly, a change in density could indicate that a liquid or solid is impure and contains contaminants. Calculating density seems straightforward as it simply involves dividing the mass of the matter by its volume. However, in practice, this process can be complicated, tedious and inaccurate. Luckily, density can be determined much more quickly and easily using an analytical balance, using a variety of available methods. One of the most popular methods is the buoyancy technique, which can be carried out in the straightforward manner of using an analytical balance fitted with a special density kit. The most common setup involves a beaker placed on the balance with one weighing pan above the beaker and another suspended inside. The beaker is filled with a reference liquid of known density such as water, ethanol, and sodium chloride solution. The basic steps involved are to weigh the sample in air, then weigh the sample again in the reference liquid and finally calculate the density based on these measurements.

Function: Quality Control Testing
Description: Quality checks that include weighing must be applied to random samples from every production batch. Ten or more samples should be weighed and each piece has a correct weight, so the measurement must fall within these tightly defined tolerances and the scale must not show any abnormalities. Therefore, a highly accurate and reliable balance is required. Quality control tests can be carried out using plus and minus weighing, which is a very simple weighing function that is possible on any scale that has a TARE function and supports negative weight values. It is ideal for comparing items to a known weight for quality control purposes. Each scale works differently, but the basic procedure involved placing a weight or sample on the scale that weighs the ideal amount or target weight and pressing TARE to zero the scale. The original sample must then be removed and the samples added to be checked one by one. This will result in the scale displaying the deviation (positive or negative) from the sample weight.

Function: Parts Counting
Description: A common challenge in the manufacturing or packaging industry is determining whether or not the number of parts in a batch is accurate. The traditional way is to count them by hand, which is time consuming and can entail human error. Using a balance however can make the process faster and more accurate. Parts counting is an advanced feature that is available on a variety of scale types, allowing the loading of a collection of identical items onto the scale and the automatic counting of how many are present. The feature works by supplying the scale with a sample of the items to be counted so that it can work out the weight of a single unit. It then uses this value to count items quickly. This is used extensively in quality control applications for counting manufacturing parts or for counting finished products quickly.

Function: Dynamic Weighing
Description: Dynamic weighing refers to the weighing of moving objects such as animals. It is often necessary to weigh live animals to adequately monitor their health and baby animals must be weighed frequently to ensure that they grow up healthy. The dynamic weighing feature on a balance can take accurate measurements when the subject is moving. Dynamic weighing works by measuring the average weight based on the force exerted by the animal over an extended period of time. Once the internal calculation is completed by the balance, it will hold the value

For more information about any of the above balance functions, or to find out which weighing balances could benefit your business, contact a member of our team today. We would be happy to help. Checkout the balances we offer here.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

What Is A Microbalance ?

What is a microbalance?

A microbalance is a class of balance designed to measure the smallest samples, often in the sub-microgram range. The instrument is considered to be the highest precision of all kinds of lab balances.

A microbalance consists of two components - one component containing the electronics and another component containing the precision mechanical measuring cell. The separation eliminates the effects of temperature on the weighments.

Microbalances offer a capacity of up to 10.1 g with readability down to 1 µg (0.000001g). Ultra microbalances offer an incredible full resolution of 61 million digits, with a capacity of 6.1 g and 0.1 µg readability (0.0000001g). This high sensitivity in microbalance design allows for the weighing of sample quantities with weight as low as 30 μg. 

Microbalances and ultra microbalances are frequently used in:

-          Product testing
-          QA labs
-          Chemistry labs
-          Mining
-          Medical device research (to check critical component uniformity)

Checkout this blog post to learn more about where and how microbalances are used.

Operational considerations:

Microbalances are extremely sensitive – environmental influences and user interaction can significantly affect measurement stability and accuracy. All vibration sources should be eliminated and air currents, dust, temperature/humidity fluctuations should be minimized to obtain peak performance. Microbalances should be used in environments with stable temperature and humidity. The balance should be away from vents, windows, and doors. A solid, dedicated workbench free from drafts and high traffic areas is the best location for the balance.

On first use, let the microbalance “warm-up” for at least six (6) hours to stabilize at ambient conditions.

Samples should be acclimatized to room temperature and should be handled with tweezers. When placing the sample onto the microbalance, the door should be opened to a minimum degree, for as short a time as possible.

Always wear gloves while working with microbalances to avoid fingerprints and oil from hands. These natural oils from the body can have an impact on the results. To start weighments, open the door and place a container on the pan using tweezers. Close the door and allow the weight value to stabilize. Tare the microbalance to capture the weight of container or weighing boat. Dose the sample outside the weighing chamber to avoid spills in the balance and then place the sample on the weighing pan. Close the door, wait for stability, and record the net weight. Repeat the procedure until desired weight is reached. A microbalance is highly sensitive to movement - do not touch the bench while waiting for the balance to stabilize. Clean the balance, tools and workspace after each use.

Calibration

The accuracy of a microbalance is dependent on accurate calibration - performed by a qualified service provider only. Quality service providers will produce a calibration certificate indicating that the microbalance is working correctly. Users should routinely test the balance to detect potential issues in performance within a calibration interval.

It is highly recommended that microbalance users work with a calibration laboratory that is ISO 17025:2017 accredited. This accreditation provides the calibration laboratory’s scope and procedures.

Checkout the balances we offer here.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

The Main Components Of A Truck Scale.

Anatomy of a Truck Scale

When things go awry with your truck scale, it can be difficult to understand the technical lingo your scale technician might use when diagnosing the issues. Knowing exactly how your truck scale works will make you a better-informed consumer when you need to repair a part on or replace it entirely.

There are many different components in a truck scale that work together to provide an accurate weight. The scale contains a combination of mechanical and electrical components working together to provide a stable weighing environment. Not all of these components are found in every type of truck scale, however. The three main types of truck scales you’ll find today are electronic, hydraulic, and mechanical (although there are fewer and fewer mechanical truck scales left each year).

Mechanical Components

Most of the mechanical components on a truck scale are located outside with the weighbridge. Fifty plus years ago (and older), most of the truck scales installed were completely mechanical pit style truck scales. Fully mechanical truck scales generally consist of the following:

• variety of large levers (carbon steel or cast iron)

• pivots and bearings

• stands and chairs

• weighing beam inside the office or scalehouse

If you had an issue with a mechanical truck scale, more often than not a cast part was broken or a weld broke loose on a fabricated part.

Nowadays, most of the truck scales you find installed are either electronic or hydraulic. The only “mechanical” parts on these types of scales consist of the following:

• the weighbridge itself (usually split into multiple panels)

• base plates, top plates, shims

• pins, nuts, bolts, etc (used to prevent motion or keep things tight)

• hardware related to checking / position alignment

Load cell system

The load cell system is the most important part of your truck scale and it is often where the most issues occur. To better illustrate our point, we will consider a standard 70’ truck scale. Whether electronic or hydraulic, this length scale will usually have eight (8) load cells and a summing component.

In an electronic truck scale, you will have eight (8) electronic load cells. Each individual load cell will have a strain gauge encased in the body of the load cell. Often, these load cells have more advanced computer boards in the body of the cell as well. In addition to the strain gauge, each load cell will have a cable protruding from one end, generally 30 – 60 feet long. The cable is often made of six (6) conductors, or individual wires, a braided shield, and a PVC jacket that is sunlight and moisture resistant. The heavy-duty jacket ensures good abrasion resistance as cables continually wear. The eight (8) individual cables from each load cell terminate on a summing board which is enclosed in a watertight housing. There can be two summing boards with four load cells each and an interconnect cable connecting the two boards. To learn more about electronic load cells checkout this blog post.

On a 70’ hydraulic truck scale, you will still have eight (1) load cells. These load cells are completely immune to lightning and water. The load cells are connected to a hydrostatic totalizer via 1/8” copper (or stainless steel) tubing. The tubing connects to the load cells and totalizer with special fittings. The totalizer converts hydrostatic pressure from each of the eight (8) load cells into an electronic signal through the single compression style electronic load cell which is installed at the bottom of the totalizer stack. To learn more about hydraulic load cells checkout this blog post.

Homerun cable

The homerun cable is the main artery that connects the scale to the digital weight indicator. Similar to the load cell cable, the homerun cable is often made of six (6) or eight (8) conductors. The homerun cable generally has a braided shield and a PVC jacket that is sunlight and moisture resistant. The lower the gauge of the homerun cable (lower gauge = fatter cable), the longer distance you can have between the truck scale and the digital weight indicator.

At the end of the day, the purpose of the homerun cable is to provide the input voltage (excitation) to the load cell system, and then to return the output voltage (signal) back to the digital weight indicator.

Digital weight indicator

The digital weight indicator is the brains of a truck scale. The indicator provides the input voltage (excitation) to the load cell system; receives the output voltage (signal); and converts the analog signal to a digital signal via the A-D board (A to D or analog to digital). The digital signal is then displayed on the display board showing the weight currently on the scale.

The indicator is also where you connect all other cables into the system. The most common cables connecting to the digital weight indicator include:

• Power (usually 120VAC)

• Homerun cable

• Communications cable (to connect to peripheral devices)

• Copper grounding cable

More often than not, truck scale users will identify that they have a problem with their truck scale because the indicator will not be displaying the proper weight. To see what indicator we offer click here.

Peripheral devices

There are a variety of devices you can connect to your truck scale. The list below covers the majority that we see in the field on a day-to-day basis.

- Printers: print inbound / outbound weight tickets for drivers. Includes truck number, date and time, as well as the gross, tare, and net weighments

- Remote displays / scoreboards: the devices are connected to the indicator via two (2) conductor communications cable. The remote display receives a digital RS-232 signal from the indicator and displays an exact match of the weight. Occasionally, truck scale owners will have issues with their scoreboard and not the scale. Scoreboards have a variety of electrical components that are susceptible to failure. Checkout this blog post to learn more about whether you are legally required to have remote display for your truck scale.

- PCs: nowadays everything is connected. Scales are being connected to PCs via serial cables (RS-232), ethernet cables, and USB. The data streaming into the PC must be interpreted by the computer and there must be a good path for the data to travel

-  Ticketing software: There are several different types of software available and these are generally industry specific. The software can provide basic ticketing and inventory management. Depending on the package you get, you can also do all of your billing and accounting integration through the software

- Notification devices (horns, stack lights, buzzers, etc): you can connect a variety of devices to the indicator, and these devices can provide an audible or visual alert that there is weight on the scale

- Intercom systems: there are many intercom products on the market today for truck scales. Not many are high quality. Due to noisy truck engines (and surrounding ambient noise), the best intercom systems have noise cancellation features.

-  Gates: Gates can be controlled by truck scale indicators based on certain triggers. Once a certain trigger is achieved, the indicator will communicate with the gate to open / close. We often see this type of set up with pay to weigh operations.

- Guard rails: Guard rails are an instrumental part of every truck scale. Most truck scales sit 18” or more off the ground. Drivers are notorious for driving their semis and dump trucks off the side of the scale and that can cause substantial damage to the mechanical and electrical components of the scale. To prevent this from happening, truck scale owners can order their scale with guard rails or install aftermarket ones. Guard rails range from:

•    Standard 8” high (safety yellow or matching the scale)

•    24” + dual pipe guard rails (primarily used on sites regulated by MSHA)

•    DOT style guard rails

•    Custom guard rails: as an example, American Scale builds guard rails out of 8” schedule 40 pipe. This set up is so stout, it either guides the truck(s) back onto the scale or damages the vehicle, saving the scale.

 To see what truck scale accessories and peripheral American Scale offer click here.

How American Scale can help

When functioning properly, these parts seamlessly work together to keep truck scale weighing accurately and precisely, time over time. However, sometimes one or more of these components can malfunction, which can stop the entire process and interrupt your life.

The expert technicians at American Scale have seen it all in our 75 years serving the Southeast and we understand how detrimental a malfunctioning truck scale can be, especially when you have long lines of trucks backed up. If your truck scale isn’t working correctly or you suspect it’s not accurate, contact us today so one of our experienced technicians can diagnose the problem and have your system back up and running in no time!

Finally when it comes to purchase a new truck scale checkout our wide range of options we offer.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Axle Scale vs Full Size Truck Scale?

We are often asked what are the differences between a full size, say 70ft truck scale, and an axle scale.  There are few key features that differentiate an axle scale from its large brother.

What is an axle scale?

As the name implies an axle scale is a weighing system designed to weigh the individual axle groups.  The weighments are completed one axle set at a time and then all the axle weights are summed to provide the total gross weight of the truck.  This is much different than a full size truck scale where the entire truck is weighed at one time.

Legal For Trade:

If you are using your scale in any legal for trade weighing operations then an axle scale cannot be used.  Axle scales are not considered Legal For Trade.  This is because as each axle group is weighed individually there are slight errors and therefore the overall accuracy of the scale is not within national testing standards.  Bottom-line, if you are looking to weigh trucks legal for trade then you can use an axle scale.

Benefits of an axle scale?

Although axle scales cannot be used legal for trade they work well in many situations.  They are great for gathering weight data to ensure trucks don’t leave a facility overloaded per DOT standards.  They also take up significantly less space than a full size truck scale.  This is a huge advantage for facilities with limited real estate to locate a scale.  The footprint for an axle scale is only 33% of a full size truck scale.  Axle scales are also more economical.  This is because the scale itself is much smaller and requires less materials to construct.  Similarly, any concrete foundation work is much less with an axle scale vs a full size truck scale.  Finally, not all axle scales require installation requiring concrete foundations.  Many can be installed on existing flat pavement and are therefore easier to install and move in the future if needed.

Axle Scales & Weigh-in-Motion?

A unique benefit of an axle scale is their ability to offer weigh-in-motion.  This means the truck does not have to stop on the scale, instead they drive over it at a slow speed and the scale does the rest.  Although the accuracy is slightly less, weigh-in-motion provides operational benefits since more trucks can be weighed faster since each truck does not have to stop.  Most weigh-in-motion axle scales boast 1-2% accuracy.  Keep in mind that not all axle scales offer this feature.  Many axle scales are simply static scales that sum of the total axle weights at the completion of all axle groups being weighed.  

Popular Axles Scales

There are a number of manufacturers of axle scales.  Of note is InterComp Scales, B-Tek Scales, and Cardinal Scales.  Each has their own models and options; see below for a few popular ones. Also checkout our Axle Scale page.

Intercomp

Intercomp LS-WIM Axle Scale

Intercomp AX900 Axle Scale

B-Tek

B-Tek AX300

B-Tek Ax200

Cardinal

Cardinal 760PS Axle Scale

Cardinal SWIM Axle Scale

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Do I Need A Truck Scale Scoreboard?

So you just purchased and had your scale service company install your brand new truck scale.  Then you are asked whether you would like to have a remote display for your truck scale?   Depending on your experience with truck scales your first question might be “What is a remote display”?  Second question you might ask is do I have to have one?

In this blog post we will help answer both of these questions and more.

What are remote displays?

Remote displays or scoreboards are large digital displays that show the weight data from your scale indicator.  They are normally mounted to a pole or other stand so that a truck driver can see his/her weight when on the scale.  This is important because most times the truck driver can not see the scale indicator since it is located inside an office or scale house. 

What’s needed to make my remote display operate?

In order for your remote display to work you will need a few components.  First you will need a source of communication between your scale indicator and the remote display.  Most often this is via RS-232 protocol via a wire communication cable.  Less prevalent is wireless options that require a transmitter and a receiver.  The wireless option eliminates the need to run hard wire cabling which can be beneficial if you have large distances / parking lots / other obstructions between the indicator and remote display.  Second you will need an electric power source to run the remote display.  Normally a standard 110VAC outlet/ receptacle is all that is required.  Finally, you will need something to mount the remote display onto.  Metal poles are often used and are a great option.  More economical are wood poles.  Also an option is mounting the remote display to the scale house itself.  The main considerations for mounting are that the remote display is secure and will not move in the wind and that the location allows for the truck driver to have a clear unobstructed view.

Do I have to have a remote display?

The answer is it depends.  First it depends if you are using your scale in a legal for trade operation.  If you are using the truck scale in a LFT operation then most likely you will need a remote display.  On the flip side if you are not using your scale in a legal for trade operation you are not required to have a remote display.  Second it depends on the state in which the scale is located.  So, if you are using your scale in a LFT operation then you must adhere to your state's weights & measures regulations.  As an example, in the state of North Carolina remote displays are required for all truck scales.  In the state of Virginia, they are also required and they must display “00” when the scale is empty; displaying only one zero “0” is grounds for the scale being rejected.  As a general rule and for improved operations overall we always suggest truck scales have a remote display.

What options are there for remote displays?

Remote displays come in a range of sizes, shapes, and finishes.  The most common is the 4-inch remote display.  This means the digits when displayed will be approximately 4 inches tall.  Other common sizes are 2-inch and 6-inch.  In addition to the size, remote displays can also have integrated red/green lights.  They are useful when needing to signal truck drivers when to pull onto and off of the truck scale.  More advanced remote displays are also capable of displaying text / words not just numbers.  This allows for messages to be flashed to truck drivers such as instructions on how / when to pull onto the scale.  To learn more about the remote displays American Scale offer checkout our scale accessories page.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Why Use A Microbalance?

Three (3) reasons to use a microbalance

When small weight variations may make a huge difference, such as in product testing or QA labs, consider a microbalance.

Three reasons to use a microbalance include:

1.      Sensitivity. Microbalances can take a precise measurement of weight of an object of relatively small mass, such as a million parts of a gram. Comparatively, a standard analytical balance is 100 times less sensitive. Microbalances are also very sensitive to exposure to air currents, dust, and thermal fluctuation. Because of this, microbalances should be placed in a hood or enclosure when in use. Some models offer air buoyancy correction software, which compensates for fluctuations in air density.

2.      Precision. These balances are designed to meet exacting production standards. Laboratory researchers use microbalances for checking uniformity in critical components.

3.      Features. Depending on the model, features can range from a built-in ionizer and anti-static glass breeze break to improve weighing by eliminating static to advanced weighing technology to maximize performance in strictly regulated environments. Some microbalances offer technology that enhances the user experience specifically for complex applications.

Environmental conditions may cause weighing variations. If the load cell of a micro balance is disturbed, either by sample loading or environmental exposure, the instrument will need to settle completely before accurate measurements can be taken. Therefore, a vibration isolation system’s settling time is a key criterion affecting the accuracy of these instruments.

Now that we know when and why we would use a microbalance, let’s consider how to achieve optimal performance:

1.      Choose a Stable Weighing Table in a  Quiet Place to Set Up Your Balance.

• The table should be solid-built and, whenever possible, be made of stone or synthetic stone.

• Avoid causing the tabletop to sag or deflect even slightly; for example, never use it to prop up your arm.

• Set up the balance in a vibration-free location. Ensure that there are no machines or engines that generate vibrations or  electromagnetic fields near the balance. Magnetism must be ruled out (e.g., tables may not be made of stainless steel).

• Do not position the table in the middle of the room, but near a wall or, even  better, in the corner of a room, as this  is where the vibration amplitudes are  generally at their lowest.

• Avoid exposing your balance to sunlight and infrared radiation emitted by lamps or heaters.

• The location may only be slightly ventilated. Exposure to drafts needs to be avoided, and the air flow rate should be below 0.2 m/s.

• Cold air currents from air conditioners may not pass directly across or over the draft shield, as this can result in an inversion layer of air inside the draft shield. This, in turn, can cause unstable weight readouts.

2.      Work in the Lab under Consistently  Constant Climate Conditions.

• Avoid significant temperature changes or spikes.

• Keep the relative humidity as constant as possible. Prevent the relative humidity from dropping below 40%, as this will  significantly increase interference by static electricity.

• Use climate sensor options to monitor climate conditions (temperature, barometric pressure and  relative humidity) if your microbalance has this feature

• Use the options to eliminate electrostatic influences. Electrostatic charges on glass vessels dissipate only very slowly, particularly when these vessels have very clean surfaces, especially when they are used freshly from a laboratory glass-ware washer. Electrostatic influences are easy to detect by the continuous drift of weight readouts. Increase the air humidity to levels up to 60%, and use an ionizer to reduce these effects on the resulting weight readings.

3.      Ensure That the Balance Is  Leveled and Calibrated.

• Routinely calibrate the balance following the internal calibration procedures.

• Moreover, routinely check the balance using an external, certified weight.

4.      During the Measuring Sequence,  Ensure  That ...

• the vessels used are acclimatized next  to your balance; i.e., have adapted to the temperature conditions in the same room.

• you do not touch the container with your hands when positioning it on the weighing pan or in a sample holder.  Touching the sample vessel with your  hand usually  increases the temperature of the vessel. Buoyancy and air current effects influence weighing results. Remember that it takes ten minutes for these effects to subside. Use a pair of tweezers or forceps to position the vessel.

• Avoid placing your hand inside the draft shield to ensure that no unnecessary  interchange of air outside and inside the draft shield takes place and that no heat  is transferred into the draft shield.

• Avoid touching a vessel with your bare  fingers at all times, as a single fingerprint  can weigh up to 50 μg and therefore have  a major impact on the accuracy of your weight measurement result.

• When weighing, ensure that no powder  falls onto the weighing pan next to the vessel, as this will mean that the displayed sample weight is not what is actually in the vessel.

• Avoid the complete interchange of air when opening the draft shield by opening only one door, where possible. Opt for using the draft shield learning capability to open the door only as far as actually necessary.

• Carefully place the tare container on  the weighing pan or in the sample holder.  Avoid applying any excessive force.

• Do not lean on or against the weighing  table or rest your arm on it during  the weighing procedure.

 Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

What is an Analytical Balance?

Analytical Balances:

An analytical balance (or lab balance) is a class of balance designed to measure small mass in the sub-milligram range. Analytical balances are highly sensitive and accurately measure mass with readability ranging between 0.1 mg - 0.01 mg (0.0001 g – 0.00001 g). These balances usually have a transparent draft shield or weighing chamber to prevent air currents and dust from affecting the weighments.  

Components of an analytical balance include:

-          balance main body

-          draft shield

-          weighing pans

-          level indicator

-          adjustable feet

-          communications interface

-          calibration weight

-          power cord and other accessories

-          software

Analytical balances detect very fine increments, so the slightest vibration or breeze can impact the results. As such, analytical balances should be used in a dedicated room with as few disturbances as possible. In certain environments, these balances are installed on anti-vibration tables to increase accuracy. Analytical balances need to be monitored carefully and calibrated frequently. Most analytical balances have both automatic internal motorized calibration and calibration with external weights.

What makes analytical balances different from other balances?

Analytical balances are designed to handle very precise measurements samples. Precision balances usually have a higher capacity and readability than analytical balances with readability ranging between 0.1 g - 1 mg. Analytical balances can take longer than precision balances to stabilize and the balance must be stable in order to produce reliable results. Analytical balances are much more sensitive to changes, and can detect smaller variations in mass. For acute measurements in labs, analytical balances are the right choice.

Unlike top-loading balances, analytical balances usually have a weighing chamber that encloses the weighing pan with glass doors to prevent interference from vibration or air currents. The weighing pan is usually smaller than in precision balances, and can only accommodate small samples. Higher tolerance calibration weights are used in calibration procedures to ensure precision results.

Common features found on an analytical balance

Analytical balances usually come with many features and functions. Most of them have counting and check counting applications, for example. These can be useful when counting pills, ingredients or very small pieces. Dynamic weighing is also very useful, as it allows lab professionals to weigh unstable samples such as liquids, small animals, or insects. Percentage weighing allows for quicker, more efficient formulation, and is quite handy for chemistry and pharmaceutical applications. Accumulation ensures you can have large results despite the balance's small capacity; instead of having all the material on the balance at one time, you can accumulate the results of doses or packaging to receive a total without putting all the product on the balance at the same time.

ISO and Good Laboratory Practice (GLP) compliant reports are essential for laboratory work. Having the balance automatically fill relevant fields can save time and allow researchers to spend more time on their work and less time formatting. This is a feature that's especially important for use in quality control.

A bright, well-lit display with multilingual software allows the balance to be used in a variety of countries, or by multilingual staff and students.

Useful accessories to use with your analytical balance

Reliable and robust analytical balances provide precise results and easy data transfer with connection to peripheral devices via USB, RS232 and optional Bluetooth.

USB and RS-232 interfaces are very useful for sending data to computers and printers, which can save time and help with later in-depth analysis. Couple that with GLP/ISO compliant printouts to save even more time and efforts. You can pair analytical balances with software for further data analysis of your results. A security lock can prevent theft and make sure the balance isn't moved from the room. Quality assurance features help you comply with regulations and industry standards.

Density kits are popular accessories in labs and in classrooms, as they allow the balance to make density and specific gravity measurements.

It's a good idea to keep calibration weight sets on hand to ensure you can calibrate your balance frequently. An anti-vibration table can create a dedicated workstation and calibration station, and ensure the balance is stable and has less interference to contend with during measurements for reliable results.

For easy cleaning, you can remove the draft shield glass panels from your balance without any tools and wipe down the interior.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Keys To Selecting The Best Bench Scale?

3 KEYS TO SELECTING THE BEST BENCH SCALE

Which bench scale you need for your operation can be a puzzling question that many folks ask. Bench scales can we used in a laboratory, production area, or for check-weighing items before shipment. Below are three keys to consider when buying a bench scale. If your still unsure, one of our representatives will be able to quickly identify which bench scale – table-top scale – is best. Also checkout this blog post on bench scale basics.

SCALE CAPACITY AND SIZE

A bench scale or table top scale can serve many uses. Scale manufacturers keep this in mind. The first thing you should consider is the maximum weight value you will be putting on the scale. By knowing your capacity, you will then be able to determine how you would like to read the weight. Bench scales can read 10-pound increments all the way down to 0.001-grams. A bench scale used for shipping small boxes would not be ideal for measuring ingredients. Ask one of our representatives how we can help determine which bench scale is right for you. Performing scale calibrations would help you figure out the capacity of your scale If your load cells (analog or electronic load cells) are under capacity of what you typically weigh, then you could affect the lifespan of your scale.

POWER SUPPLY

Most bench scales have the option of being battery operated or powered by standard 110VAC. Laboratories do not always have extra power outlets available. The option of having a battery powered scale can be very convenient. Normally, battery powered scales are for smaller weighing – ingredients  and chemicals. A bench scale used for higher weights – 10+ pounds – will required a 110VAC power outlet. Consider which type of power supply will be most efficient for your operation and how often the scale will be relocated before making a purchase.

WASH-DOWN SAFE

Bench scale systems come in all types of IP / waterproof ratings. Typically a stainless steel setup will be able to handle a washown environment over a steel deck. Confirm with your service provider if the scale will be in a wash-down environment prior to making a purchase. Wash-down safe bench scales are readily available and used most often in any environment outside of a lab setting. Along with waterproof ratings, bench scales also have a dust rating to consider if you are needing intrinsically safe instrumentation.

Learn more about the bench scales that American Scale Offers here

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Weighing Applications In Production

Weighing in Production: Value through Data

When most people think of weighing, their mind tends to picture “Retail”.
“How many ounces of cookies are in this box?”
“Do I need 1 or 2 gallons of milk?”
“How many lbs. did I gain over the holidays?”

For those of us in the material handling industry, we may think a little more beyond retail, but still primarily “post-production”:
“How much lumber is on this truck?”
“How much does that pallet weigh?”
“How much “stuff” did we make today?”

In fact, there is a place for weighing throughout the entire supply chain; raw, refinement, production, quality control, packaging, logistics and retail. Having a good understanding of effective placement and use (including proper scale selection, maintenance, and calibration) of these tools can be incredibly beneficial in reducing overhead, identifying bottlenecks, and in the end increasing production and/or efficiency and profitability.

In production, scales do more than “weigh”. They create value.

To exemplify, let’s imagine you operate a facility that makes plastic fenders for golf carts. Of course, as we walk through, actually consider your own position, where it falls within the overall supply chain process, and if you are taking advantage of all of the weighting and cost saving tools that are available.

Let’s assume our fenders are going to be molded of thermoplastic resins. These are materials that become liquid in high heat only to harden again when cooled. Easily molded into various shapes and structures, this gives thermoplastics applications in many industries.

To visually grasp the extreme number of materials and production options of thermoplastics, let’s list out some of the most common here: Commodity Resins: ABS, Acrylic, High Density Poly, Ethylene, Polypropylene, Polyethylene, Polystyrene, PVC, Styrene, Engineered Resins: Acetyl, PBT, PET, Polycarbonate, Peek, PEI, PES / PSU, PPE, Nylon, PPS, TPE, TPU, Teflon, TPR, Specialty Resins:, COC, COP, LCP! AND… of course each of these types have multiple different producers, each with their own “recipe” to create specific characteristics!!! To say there are thousands of varieties is not an exaggeration:

Scale use 1: Raw production

Each of these different choices are individually manufactured in unique chemical production facilities which would use a variety of scales (silo/tank scales, gain-in-weight/loss-in-weight feeders, belt scales, pneumatic transporters on load cells, etc) in their manufacturing process. But, we will jump ahead to our plant.

 
Scale use 2: Raw Supply/Logistics

Let’s say, our material requires a resin, a plasticizer, a fiber, a heat stabilizer, a UV stabilizer, and various pigments (for color) In actuality there are probably more! These base materials are typically transported by rail or truck, each of which would be weighed by NIST certified scales prior to leaving their respective manufacture point for both production verification as well as state and national “legal for trade” and “over the road” requirements and limitations.

Scale use 3: Intake

Once arriving to our site, these containers are often “re-weighed” to verify delivery quantities. Done by using any combination of rail scales, truck scales, weight monitoring a “receiving vessel” (a silo on load cells for example) or checking bulk packaging like a “bulk-bags” with a forklift scale, at this point our raw material has become an “ingredient”.

Scale use 4: Ingredient inventory management

In order to efficiently produce, we would need to know how much ingredient we have on hand at all times. Primarily, this prevents us from running out of an ingredient and halting production (extremely costly), BUT… this also allows us to make smart economically driven decisions, like when and how much of an ingredient to purchase so we might take advantage of advantageous market pricing, bulk discounts, logistics savings etc. While some plants might use volume measurements (level probes) to track ingredients, bulk densities can vary, so using scales to WEIGH the materials on hand is much more accurate. Volume varies, weight does not.

Scale use 5: Batching/Quality Control

Now its time for us to make our material. Here, the use of scales if of utmost importance. As we bring our six (in reality more) ingredients together, we must be absolutely sure we have the right amount of each. Too little UV stabilizer would cause our golf carts to “yellow” or become brittle, too much plasticizer could lead to our panels being flimsy, or too much or too little pigment would lead to variability in the color our finished product (no golf course would want 15 different shades of cart!) Depending on how the ingredients are transported to the batching/blending tank, this weighing might occur through multiple types of scales; again, gain-in-weight/loss-in-weight feeders, belt scales, pneumatic transporters on load cells, or in some cases simply hand scooping an ingredient into a tote sitting on a small bench scale to be manually added. All of these are yet another check point where we can make sure we are optimizing our ingredients (cost savings), identifying points of ingredient loss (waste), reducing the chance of “bad batches” (waste reduction), and quality improvement (higher value final product) each of which improves profitability.

Scale use 6: Production

As we now put our mix into the molds, we again would weigh out. This makes sure we have sufficient material to form the entire piece (eliminate voids) but that we do not OVERfill (and create waste). Additionally, supplying the molds or injection equipment with the proper amount of material increases the longevity of the machinery (maint. costs reduction and downtime avoidance) plus reduces additional labor costs needed for post-production finishing,

Scale use 7: Finished Goods Quality Control

Post trimming and finishing, we would now scale weigh our finished panel during the quality control process. This additional quantitate check measures product consistency and “red flags” potential concerns. This scale might help us identify panels that are too “thick” (a waste of production materials), or too thin (a source of customer concern), each of which might also suggest the need to examine the production line to find the root cause of variance, perhaps preventing expensive downtime or repairs.

Scale use 8: Packaging/Logistics

Now as we package our panels for transport to our customer, we once again would scale weigh and label each panel if selling individually, or weigh and label a pallet holding numerous. Strategically planning packaging and transportation weights may allow us to take advantage of shipping savings.

This quick example of a single product has utilized DOZENS of scales, each with an opportunity to improve efficiency, reduce costs, and increase profitability.

Again, in production, scales do more than “weigh”, they create value.

Of course, we could imagine this for any material, product, or industry. Maybe trees in a logging yard, trucked to a mill, processed with other chemicals to make a cookie box. Grain from the field, sent by train with other ingredients to a bakery to make those cookies. Bulk Bags of silica from a quarry, mixed with additives to form the glass on top of our personal scale.

We invite you to think about your own position and products and how property selected, installed, maintained and calibrated scales could improve your operations and success.

Let us know how American Scale Company can be of help.

The Author has over a dozen years experience in dry material handling, processing, manufacturing and weighing including consultative system design, equipment and component recommendation, provision and supply.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Types Of Belt Scale Maintenance

Regular Belt Scale Maintenance

Regular belt scale maintenance is imperative to make sure your scale stays in proper working order and lasts for a long time. This maintenance should include clearing the scale area of debris, checking the condition of the idlers, check the scale frame and the conveyor belt, and zero testing the scale daily. Before maintenance can even begin make sure you install your belt scale in the correct location, checkout this blog post to learn more.

Clean Around The Belt Scale Frame

The most important part of belt scale maintenance is keeping the weigh frame clean. Debris in the scale area is generally caused by material falling off the conveyor belt and building up. This material can get wet and even freeze. Material buildup will cause issues like mechanical binding, inaccurate zero test results, and incorrect totalizing.

 If a belt scale weigh frame has just five pounds of buildup, the scale could register several extra tons every hour, causing a false totalization. In colder weather, we recommend running the conveyor belt for 10 to 15 minutes without a load to warm up the belt and make it more pliable.

Don’t Forget About The Belt Scale Speed Sensor

The speed sensor on the belt scale also needs periodic attention. The speed sensor (wheel sensor on return belt or a shaft-mounted encoder), it must be clear of debris use.

Keep Your Belt Scale In Top Shape

Performing a daily zero test on the belt scale is recommended and will help the user determine if and when the scale needs to be inspected. In good weather, the zero test should have normal results close that are showing good repeatability. If the zero test isn’t showing good repeatability, the belt scale should be checked for ice buildup.

 After clearing debris away from the belt scale frame, perform another zero test, and then run a span test (or static calibration test). If the span test results are not normal compared to periodic span tests, it is best to call a certified scale dealer to perform a thorough inspection and any calibrations necessary.

Belt Scale Calibration Program

Having a regularly scheduled calibration program with your scale company is always recommended to keep your belt scale weighing and performing at top shape. At the end of the day, performing a material calibration is the best method to use.

To learn more about the different belt scale manufactures, checkout this blog post.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

How To Test My Magnet?

Testing Your Magnet

Because magnetic fields are transparent to the human eye, measuring their strength requires specialized tools that measure the working air gap of the magnetic circuit. Currently, there are two accepted ways of testing your magnetic separation equipment and this subject itself is not without controversy. The first is with the use of an instrument called a Gauss Meter or Magnetometer and a probe, and the second is with a Pull Test Kit using a scale and a selection of different sizes of ferrous test pieces; a ¼” ball, a ½” ball, a 1” ball and a 1” x 3” plate. Make sure you understand the different type of magnets prior to testing, checkout this blog post to learn more.

Gauss Meter

A Gauss Meter is an electronic device that measures the flux density at any given point on your magnet. As the probe is pressed against the surface of the magnet it senses the flux density and translates it into an electrical voltage read by the gauss meter. Gauss readings are displayed on the meter. When the maximum number is found while moving across the face of the magnet (usually at a pole piece), it is recorded.

PROS

It is a scientific piece of equipment that can be calibrated. In clinical environments where the working air gap can be plotted and the probe placed repeatedly in the exact same spot within the gap, Gauss is incredibly accurate.

CONS

In real-world environments Gauss testing has serious limitations. Gauss profiles change significantly depending upon the location and angle at which the probe is placed within the working air gap in relation to the line of flux travel. Because magnet circuits vary from one magnet to the next, and because of “human error,” accurate readings are difficult to attain making the manually taken gauss value an imprecise determination of the magnets strength. Simply placing a different amount of pressure on the probe to the surface of the magnet will create drastically varying results. Because of the length of time that lapses between testing, it is not uncommon for different individuals to execute them, which further limits accuracy. Lastly, any mechanical damage to the probe or cable will degrade the precision of the instrument. They are essentially “consumables” that require regular replacement. These factors add time, cost, and technical training to the equation.

MPI’s Magnetic Pull Test Kit

A Pull Test Kit utilizes a compact digital scale or a spring scale, and a series of ferrous test fixtures (a ¼”, ½”, and 1” ferrous ball and 1” x 3” ferrous plate). The magnetic pull strength is measured by using the calibrated scale and a ferrous test piece to determine the breakaway force, typically measured in pounds or ounces. The test fixture has one end attached to the scale and the other end securely attached to the working area of the magnet at a predetermined position (on the surface with a specified air gap). It is then slowly pulled away at a perpendicular direction to the magnet until it is released. The pull strength is registered on the scale.

PROS

The digital scale offered in MPI’s Pull Test Kit is also a scientific device that can be calibrated and NIST (National Institute of Standards and Technology) certified. In practical applications, the pull test approach is advantageous because the testing equipment is less expensive to acquire, more efficient to operate, and achieves more consistent repeatable values than the gauss approach regardless of the individual operator. The ferrous test fixture is drawn to the magnets peak energy point with every repetition of the test, as opposed to the gauss approach which requires the operator to find the peak energy point within the working air gap using the probe. The pull test is also performed much more efficiently than the Gauss method, minimizing production downtime.

CONS

Just as Gauss meters have evolved over the years, so have mechanical pull test kits. Akin to a fish scale, some company’s pull test kits are still offered with simple spring-loaded gauges that measure the force required to pull a small metal sphere or ball. MPI’s magnetic pull test kit is the most accurate and easiest method to test the strength of your magnets. This easy-to-use, compact gauge fits into tight areas and is battery- operated (four AA batteries included.). Boasting a capacity of 44 lbs. (20 kg), MPI’s magnetic pull test kit can measure pull in pounds, ounces, kilograms, newtons, or kilonewtons. It can maintain the last reading after release. Packaged in a hard-sided foam-padded carrying case, this compact unit includes all needed accessories and can be used to test a complete range of magnet types and configurations. The documentation generated from this test can be used for compliance in a Hazard Analysis and Critical Control Point (HACCP) plan or for documentation requirements under the Food Safety Modernization Act (FSMA).

To learn more about the magnets that American Scale offers click here.

How Often Should I Clean My Magnet?

How often Should I Clean My MaGnetS?

How often should you be cleaning your magnet is another question that is dependent upon your individual process. Obviously, the more metal you receive or produce in your process, the more frequently you should be cleaning your magnets. A general rule is the more frequently, the better. As a magnet gathers ferrous metal, the magnetic field is dispersed over a larger surface area. This happens because ferrous metal is paramagnetic, meaning it takes on the properties of the magnetic field. When this happens, the magnetic field strength is reduced. It is better to begin cleaning your magnets more frequently after the magnet is placed and reducing the frequency as possible without jeopardizing the effectiveness of the piece of equipment. Each manufacturing facility will be different as well as locations within the same facility may very well need to be cleaned at different intervals. “More is better.” To learn more about the lifespan of a magnet checkout this blog post.

Establishing A cleaning schedule:

1. After installation, inspect your magnet after the first hour of production

2. If an insignificant amount of metal is observed, return in 2 hours to inspect magnet

3. If magnet continues to have insignificant amount of tramp metal, it is recommended that maximum time between cleaning is 8 hours

4. If significant amount of metal is found on magnet, increase the cleaning interval as required to ensure the magnet does not reach maximum tramp metal capacity

Key to magnet performance is also testing, checkout this blog post to learn more about testing your magnets to ensure proper function.

What's The Lifespan Of A Magnet?

How Long Will My Magnet Last?

Your permanent magnet should lose no more than 1% of its magnetic strength over a period of 100 years provided it is specified and cared for properly. There are a few things that may cause your magnet to lose its strength:

HEAT:

Heat above the maximum level rated for the magnet material in your separator will decrease the strength of the magnet. Standard rare earth material from MPI has a maximum temperature of 176°F and standard ceramic material has a maximum temperature of 400°F. Higher temperature materials are available and may have been used in your system. Consult the factory if you have questions on what the maximum temperature is for your system.

IMPACT

Sharp impacts to the magnet from physical abuse or handling can result in the decreased magnet strength. The magnet material inside your separator is brittle and these impacts can lead to fractures in the material, weakening its strength.

WELDING

Welding on or around the magnet can lead to decreased magnet performance. This can be a result of the heat or current generated from the welding process.

LIQUID INGRESS

If your magnet housing is compromised, moisture can enter the housing of the magnets. This can lead to oxidation of the magnet material which will eventually lead to a weakened magnetic system. If the housing is compromised, the magnet should also be replaced for sanitary concerns.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Magnets: What Are The Different Types?

Magnets magnetically capture and control ferrous contaminants in material process systems. The proper magnetic applications and magnet placements will help you achieve success for removing tramp metal from your product flow.

Magnetic Application – Primary Magnets

Primary magnets are designed to be used in high volume process flows placed inline so as not to introduce any foreign contaminants from external sources into your production facility. They will remove large amounts of ferrous tramp between cleaning cycles giving you peace of mind. These magnets are typically located in plant receiving areas and handle large amounts of materials that tend to damage equipment or bridge in many magnet applications. The magnet circuit design is such that the magnetic field reaches out is maximized while maintaining adequate holding values to gather large amounts of tramp before reaching the saturation point. Primary magnets help to identify risks associated with bringing in ingredients from outside sources allowing you to monitor your vendor product quality.

Primary Magnet Function:

• Process high volume product flows

• Remove incoming tramp ferrous

• Retain large volumes of tramp ferrous between magnet cleaning cycles

• Vendor monitoring

Where it is used:

Plant receiving areas

MPI Primary Magnets:

Chute Magnets, Free-Flow Magnets

Magnetic Application - Secondary Magnets

Secondary magnets are used in processing areas in front of sensitive pieces of equipment for protection, as well as throughout your process for redundancy which helps to detect process equipment malfunctions. The material flow is typically metered at this point, which enables us to specify your exact application requirements. The magnetic circuits are designed with specific functions, whether that be to maximize the magnetic fields reach out, holding force, or a combination of both.

Secondary Magnet Function:

• Protect specific plant equipment

• Detect process equipment malfunctions

Where it is used:

hammer mills, airlocks, screw conveyors, sifters, roller mills, bucket elevators, screeners, pumps

MPI Secondary Magnets:

Plate Magnets

Magnetic Applications Finishing Magnets

The function of a finishing magnet is to maintain your end product quality to your customer. Finishing magnets capture small metal fines from your process ensuring product shipped from your plant, whether going to another manufacturer for further processing or to a shelf for consumer use, contains no ferrous tramp contamination. This protects your brand reputation and financial liability for recalls, as well as consumer protection.

Finishing Magnets Function:

• Maintain end-product quality

• Ensure that the product to be shipped from the plant does not contain any tramp ferrous contaminants

• Consumer protection

• Brand protection

Where it is used:

packaging systems, bulk load-out areas

MPI Finishing Magnets:

Tube Magnets, Grate Magnets, Drawer Magnets, Pneumatic Line Magnets

So what is the best type magnet for my application?

That depends on your reason for looking into magnetic separation equipment, to begin with. Are you looking to protect equipment or the integrity of your product? Your desired results will determine which type of magnet to put into place and where. Keep in mind that no magnet is 100% effective in removing all tramp metal. The amount of tramp it is exposed to couple with the frequency of cleaning has a dramatic effect on your success. If you are finding a lot of metal on your magnet, you can be fairly certain metal has gotten by. Because of this, redundancy in your process is critical with magnetic separation equipment. You should feel comfortable in the amount of metal you are collecting on the last magnet in your process.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Who Makes Belt Scales?

Understanding Different Belt Scale Brands

If you are reading this article, there is a good chance you are in one of two camps. Either you already own a belt scale or you’ve decided that you want to get a new one. Either way, you should know there are several different companies that manufacture belt scales.

 Given there are so many belt scale brands, we thought we would try and list some here:

-          Arch Environmental Equipment, Inc. (Archweigh)

-          Belt-Way Scales

-          Bulk Pro Systems, LLC

-          Etheridge Automation (software based scales)

-          Merrick Industries

-          Pfreundt GmbH

-          Phoenix Scale Technologies

-          Precia Molen

-          Rice Lake Weighing Systems

-          Schenck Process

-          SciTronics

-          Siemens

-          Superior Industries

-          Tecweigh

-          Thayer Scale

-          Thermo Fisher (Thermo Scientific Ramsey)

-          Trimble Loadrite

-          Vidmar

-          Weigh Shark (MCR Technologies Group Inc.)

-          Wipotec OCS

This list is not all inclusive – send us the names if we left any off!

All these brands have different technologies, weigh frames (or lack thereof), and reporting capabilities. If you are looking for a belt scale or need some assistance troubleshooting one, make sure you find the right expert to help you through the process.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

I Need A Belt Scale – What Info Do I Need?

We get a lot of calls from customers that want a new belt scale and aren’t sure what information to provide us. This article will help explain some basic requirements that any scale dealer will need to start working on a belt scale project.

If you don’t know the answer to these questions – DO NOT worry! We can go through them together to figure out the best scale for your application. To learn more about the different companies that make belt scales checkout this blog post.

Info about the application / material being weighed:

Basic questions we will ask include:

1.       What type of application is this scale going to be used for?

a.       Inventory
b.       Load out
c.       Blending
d.       Batching control

2.       What accuracy are you trying to achieve?
3.       What is the maximum flow rate of the material (tons / hour)?
4.       What is the minimum flow rate of the material (tons / hour)?
5.       What does the material consist of?
6.       What is the size of the material?
7.       What is the density of the material (lb / cubic foot)?
8.       Is the material corrosive?

Info about the conveyor

Basic questions we will ask include:

1.       What is the conveyor type (stationary, stacker, portable, mobile crushing equipment)?
2.       What is the make of the conveyor?
3.       What is the model of the conveyor?
4.       What is the conveyor angle?
5.       What is the belt length (feet)?
6.       What is the belt width (inches)?
7.       What is the belt speed (feet / minute)?
8.       What is the idler spacing?
9.       What type of idlers do you have (standard trough, offset, channel inset, flat, catenary, etc)?
10.   What is the condition of the belt?
11.   Does the belt have splices? If so, what type?
12.   Is the area where the scale is going to be installed an explosive environment? 

Additional info that will help spec out your belt scale project

Basic questions we will ask include:

1.       What is the power source (110VAC, 240 VAC, 12-24VDC)?
2.       Where will the integrator (scale head) be installed?
3.       How far is the scale head from the scale frame?
4.       Do you want the scale to communicate with your control / automation system?

a.       What protocol are you looking for (Analog output, Ethernet IP, DeviceNet, Profibus, etc.)

5.       Do you want a remote display?
6.       Do you want to include a self storing test weight system (we recommend it!)?
7.       Do you want to control many belt scales from one integrator?
8.       Do you want to receive and/or monitor your data on your phone of the web?

 Last but not least, if you get us these dimensions, you are really ahead of the game!

To see what belt scales American Scale offers checkout our belt scales page.

Closing Words

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' and “How Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

Troubleshooting Floor and Pallet Scales

Troubleshooting Guide: Floor Scales

Floor scales can be one of the most abused pieces of equipment. They are often in harsh environments like factory floors and warehouses where a lot of action surrounds them. Floor scales are subject to forklift loading, rough washdowns, corrosive materials, dust, debris, overloading, hazardous areas, and more. It is important to make sure your floor scale is still operating at its peak performance despite the hazards surrounding it. Below is a list of troubleshooting tips to ensure your floor scale(s) are operating effectively and efficiently. If you follows these easy steps below and your floor scale still isn’t operating properly it’s time to call your scale service company to assist.

Issue	Probable Cause	Solution
Inaccurate weight readings	Debris, obstructions	Clean the area around and under your scale. Look for any foreign objects wedged under scale
Inaccurate weight readings	Uneven surface, uneven heights	Place scale on clean flat surface. Make sure all corners are supported evenly and not tipping
Platform rigid and not oscillating	Obstruction, debris	Clean out around and under scale; make sure no foreign objects are wedged under scale
Platform rigid and not oscillating	Broken suspension parts	Call for service
Scale stays on zero with weight applied	Broken or cut cable	Check load cell for damage. If equipped with quick disconnect, make sure cable is fully plugged in
Indicator not returning to zero	Obstruction, debris	Clean out around and under scale; make sure no foreign objects are wedged under scale
Indicator not returning to zero	Defective load cell	Call for service
Indicator display is unstable	Defective load cell	Call for service
Indicator display is unstable	Broken or cut cable	Make sure load cell cable is undamaged, call for service