When Your Weighbridge Stops Working: Why an Upgrade Might Be Smarter Than a Replacement

If you rely on a weighbridge for your operations, you know how disruptive it can be when it suddenly stops performing as it should. Whether it’s inconsistent readings, hardware failure, or outdated software, a non-functional weighbridge can quickly throw off inventory management, billing accuracy, and overall site logistics.

When faced with these issues, many businesses immediately assume the solution is a full replacement. But before you commit to the time and cost of tearing out and rebuilding a weighbridge from scratch, it’s worth asking a simple question:

Could an upgrade give you everything you need – for a fraction of the cost?

Why Upgrading Makes Sense

A weighbridge is made up of several key components: the platform, load cells, indicator, and software. Often, it’s not the entire system that’s failed – just individual elements. For example:

• Faulty load cells can be replaced with newer, more accurate models.
• Outdated indicators can be swapped out for touchscreen terminals with powerful software.
• Manual processes can be modernised with automation, traffic control, and data capture systems.
• Upgrading allows you to modernise and restore performance without the capital outlay (and operational disruption) of a full replacement.

Case Study: A Food Manufacturer’s Smart Solution

One recent project shows just how effective this approach can be.

A leading UK food manufacturer came to MWS with a serious problem: both their in- and out-weighbridges had stopped working. These weighbridges were essential for monitoring lorries delivering oils, salt, and collecting waste – meaning that every hour offline was a hit to accuracy, efficiency, and profitability.

The challenge was clear:

• Get both weighbridges operational, fast.
• Integrate with the existing infrastructure.
• Deliver an intelligent, compact system that could automate as much of the process as possible.

The MWS Upgrade Approach

Instead of ripping out and replacing the whole system, MWS delivered a targeted upgrade:

• New Indicators: The old driver terminals were replaced with advanced touchscreen GST4 units.
• Powerful Software: We integrated Giropes’ Gestruck software – a highly configurable platform that offers full weighbridge management.
• Automation Tools: The system was connected to traffic lights and an ANPR camera, enabling automatic vehicle detection and smooth traffic flow.

The result was a seamless in-and-out weighing process:

• On arrival, vehicles are weighed, logged, and processed using ANPR and touchscreen input.
• On departure, the system captures outbound weights, prints a ticket, and logs everything into a central database – automatically.

The Outcome

The client saw immediate benefits:

• Automated workflows meant fewer manual errors and faster processing.
• Real-time data and reporting helped the team make better operational decisions.
• Significant cost savings were achieved by retaining and upgrading the existing infrastructure, rather than starting from scratch.

This project is a perfect example of how MWS helps clients extend the life of their equipment while bringing their weighing operations firmly into the modern age.

Thinking About Your Own Weighbridge?

If your weighbridge is acting up, don’t assume the worst. Speak to our team about upgrade options first – you might be surprised at just how much we can do with what you already have.

An upgrade might not only save you money – it could also unlock powerful new functionality that boosts efficiency, accuracy, and peace of mind.