Fully Automated Weighbridge — RFID + CCTV + Anti-Fraud + ERP
A fully unattended weighbridge management system that automates the complete vehicle weighment cycle — RFID-based vehicle identification, CCTV verification at entry and exit, dual gross-tare weighment, net weight calculation, delivery challan generation, and real-time ERP sync — with no manual operator involvement.
Client
Logistics & Transport Industry
Logistics & Transport
Business Challenges
A dedicated operator was required every shift to manually record vehicle numbers, weights, and materials — creating staffing dependency and human error risk across every shift.
Without camera verification, vehicles could swap cargo, carry concealed loads, or repeat weighments fraudulently — causing significant material loss and billing discrepancies.
Manual weighment cycles took 8–15 minutes per vehicle. At peak hours, queues of 20–30 trucks formed at the gate, disrupting delivery schedules.
Handwritten challans were prone to errors, required physical handling between weighbridge and stores, and caused delays in material movement tracking.
Live Process Simulation
Watch the complete automated weighbridge cycle — from RFID detection and CCTV capture at entry through dual weighment, anti-fraud check, and instant ERP posting at exit.
Live Simulation
1st Weighment (Entry) → Load/Unload → 2nd Weighment (Exit) → Net Weight auto-calculated
How It Works
Every vehicle goes through two weighments — one at entry and one at exit. The difference gives the exact net material weight with zero manual input.
1st Weighment (Entry)
12,400 kg
2nd Weighment (Exit)
10,300 kg
Net Material Weight
2,100 kg
Auto-calculated · Zero manual entry
System Capabilities
UHF RFID readers at entry and exit automatically identify registered vehicles — no manual driver check-in or data entry required.
IP cameras at both gates capture vehicle and number plate at each pass. Anti-fraud engine detects swaps, duplicate weighments, and load tampering.
Gross (loaded) and tare (empty) weights recorded automatically at each gate pass. Net weight computed instantly — zero manual calculation.
Detects suspicious patterns: same vehicle weighing twice, unusual weight differentials, plate mismatches, and blacklisted vehicles — all blocked automatically.
Digital and printed delivery challans generated at exit gate with gross, tare, net, material, supplier, and timestamps — no handwritten paperwork.
Material inward/outward posted to ERP within 2 seconds of tare weighment. Supports SAP and custom ERP via REST API.
Impact & Outcomes
Outcome
GateWeigh transformed a manual, fraud-prone weighbridge into a fully automated, unmanned facility operating 24 hours a day. Vehicle throughput tripled, weighbridge staffing costs were eliminated, and no weight fraud incidents have occurred since implementation. Every material movement is tracked in real time with CCTV evidence and posted to ERP within seconds.
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