Targeted modernization of check scale equipment to improve accuracy, durability, and long-term reliability
A glass manufacturer relied on an existing check scale system positioned just before the mixer to verify batch weight and maintain consistent material flow. Over time, the equipment became severely worn due to the highly abrasive nature of the materials being processed, particularly with increased cullet content in the mix.
As chutes and hoppers deteriorated, material leakage and dusting increased, leading to raw material waste, housekeeping challenges, and environmental exposure. At the same time, legacy lever-action load cells experienced frequent calibration drift, resulting in unplanned downtime for recalibration, inconsistent batch weights, and increased operator intervention. These issues reduced overall system availability and increased operating cost, prompting the client to engage Re:Build Optimation to redesign the system for improved durability, accuracy, and long-term reliability.
Re:Build Optimation evaluated the existing check scale system and worked with the client to develop a replacement that would maintain the same overall footprint while upgrading performance and durability. The team leveraged its experience in batch process equipment design to create a solution that addressed both mechanical wear and outdated instrumentation.
The redesign focused on replacing the lever-based load cell mechanism with a modern four-point tension load cell system. This configuration improved measurement accuracy, reduced calibration frequency, and simplified long-term maintenance. Additionally, Re:Build Optimation identified cost-effective ways to improve mechanical robustness without significant increases in capital cost.
The new system features a redesigned inlet chute and check scale assembly built for improved abrasion resistance and measurement precision. Key improvements include:
Re:Build Optimation also performed control system programming updates to accommodate the new load cell configuration and ensure seamless operation with the plant’s existing control infrastructure.
Re:Build Optimation delivered a modernized check scale system that significantly improved durability, measurement stability, and ease of maintenance. By replacing outdated load cell technology and reinforcing key mechanical components, the upgraded system enables more reliable operation in highly abrasive batch environments, reducing calibration-related downtime and minimizing material loss caused by leakage and dusting. The result is improved batch house availability, lower maintenance burden, and extended equipment service life achieved through targeted, cost-effective engineering upgrades.
The system consists of:
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