Automated Split Rail Weighing System for Cattle Processing

At Brechbuhler Scales and B-TEK, we know that precision and durability aren’t optional in agriculture—they’re mission-critical. Our most recent project highlights how technical design and customer-driven engineering come together: the development of a dual split rail weighing system built specifically for a high-volume cattle processing environment.

Why a Custom Rail Weighing System?

Cattle processing facilities rely on rail systems to move carcasses efficiently through different stages of production. Integrating weighing directly into these rails eliminates the need for manual transfers, improving throughput and ensuring weight data is captured at the right point in the process. Standard platform scales aren’t well-suited for this type of continuous, overhead load handling. That’s why our customer required a rugged, rail-based solution with accuracy, speed, and corrosion resistance at its core.

Engineering the Split Rail Design

Our engineering team designed a split rail configuration capable of measuring independent loads while balancing alignment and stability. Each rail is supported by stainless steel shear beam load cells—the workhorses of industrial weighing—known for their ability to provide precise readings even under dynamic loading conditions.

The system utilizes galvanized steel housings to resist corrosion and withstand washdowns, while the load cells are stainless steel, IP-rated for moisture and debris protection. This combination ensures that the weighing system not only meets accuracy requirements but also endures the demanding daily environment of cattle processing.

Load Cell Specifications and Integration

Each rail section incorporates dual load cells for stability and redundancy. The selected models were chosen for:

• Capacity: Tuned for the expected weight ranges of carcass processing, ensuring accuracy without overloading.

• Output Sensitivity: 2.0 ± 0.1 mV/V for stable signal transmission.

• Sealing: Hermetically sealed to prevent moisture intrusion, critical for facilities with frequent sanitation cycles.

• Accuracy Class: Designed to meet or exceed OIML and NTEP requirements for trade applications.

The electrical connections are shielded to minimize noise, and the mounting design prevents lateral stress—key factors in ensuring long-term repeatability of measurements.

Seamless Integration with Existing Infrastructure

Rather than requiring the customer to redesign their workflow, the weighing system was engineered as a drop-in assembly. The split rails bolt directly into the current overhead track, preserving operational flow while introducing real-time weight capture. This integration minimizes downtime during installation and avoids unnecessary structural modifications.

Benefits Beyond Accuracy

While accurate weighing is essential, this custom system also adds:

• Traceability: Reliable weight data for compliance and reporting.

• Durability: Materials and sealing designed to extend lifespan in a harsh environment.

• Efficiency Gains: Eliminates extra handling steps, reducing labor costs and improving throughput.

What’s Next

This project is currently in its final shop phases before installation. Once installed, it will provide the customer with a high-performance, corrosion-resistant weighing system designed specifically for the realities of cattle processing.

At Brechbuhler Scales and B-TEK, we believe weighing technology should adapt to the customer—not the other way around. This project is just one example of how our engineered solutions team continues to push the boundaries of custom integrations for agriculture and beyond.