A belt scale system featuring integrated AI-driven continuous calibration checking and real-time load cell monitoring with traditional belt scales, was recently launched at the bauma 2025 trade fair.

Described by conveyor belt alignment solutions provider Tru-Trac Rollers as ‘groundbreaking’, the new system goes beyond simple weighing or measuring tonnes an hour, to deliver advanced monitoring of the health of the entire conveyor system.

Integrating with Tru-Trac’s Rip Prevent+ system, the innovation leverages AI to detect anomalies or rip events on all conveyor belt types including steel cord, pipe, and fabric belts.

“This intelligent belt scale sets a new standard,” says Tru-Trac sales manager: bulk materials handling division Tinus Ludik. “It is not just technologically advanced but also user-friendly, providing unprecedented data that conventional belt scales simply don’t offer.”

A standout feature is real-time load cell monitoring, ensuring millivolt (mV) signals remain within optimal range. Any deviations trigger proactive warnings, allowing for timely intervention and reducing the risk associated with inaccurate or inconsistent readings. By continuously assessing load cell health, the system enhances reliability, repeatability, and accuracy.

Unlike traditional systems that require manual recalibration, the new belt scale automatically detects and corrects inaccuracies. Advanced AI algorithms analyse and cross-check the belt scale readings against mass flow measurements, identifying deviations and self-adjusting to maintain precise measurements. This eliminates the need for manual intervention, improves reliability and reduces maintenance.

Beyond weighing, the system also monitors conveyor health, to ensure consistent material flow. Continuous mV readings assess belt alignment, flagging potential misalignment caused by off-centre loading.

By tracking key performance indicators in real time, the belt scale also delivers long-term operational insights, giving customers a deeper understanding of plant efficiency and productivity trends.

“The system’s anomaly detection continuously analyses operational parameters,” adds Ludik. “If any irregularities arise they are flagged instantly, allowing for corrective action before small issues escalate. This real-time oversight fosters constant optimisation and operational excellence.”