How Do You Monitor Tank Inventory by Weight?
Inside Brechbuhler Scales’ 12,000-Gallon Tank Scale Installation in Fort Wayne, Indiana
For operations that rely on bulk material storage, one question becomes critical:
How can we accurately monitor how much material is inside our storage tanks—without guessing or manual measurement?
For many manufacturers and processing facilities, the answer lies in tank weighing systems powered by load cell technology. In this recent Fort Wayne, Indiana project, the Brechbuhler Scales team completed the initial stage of a large-scale installation involving three 12,000-gallon vertical double-wall storage tanks—each equipped with a precision weight-based monitoring system.
This project demonstrates how Brechbuhler Scales delivers custom-engineered weighing solutions that improve accuracy, safety, automation, and operational efficiency.
Project Overview: Outfitting Three 12,000-Gallon Tanks with Weighing Systems
The customer constructed a new building on their campus to house:
- (3) 12,000-gallon vertical double-wall storage tanks
- Indoor tank support structures
- Integrated monitoring and control systems
Their primary objective was clear:
Monitor stored material levels by weight in real time and control upper and lower storage limits automatically.
Rather than relying on volume sensors, float systems, or manual level checks, the customer wanted a more accurate and reliable solution—one that accounts for material density variations and delivers precise data.
That’s where Brechbuhler Scales tank weighing systems come in.
Why Monitor Tank Inventory by Weight Instead of Volume?
Many facilities initially monitor tank levels using volume-based systems. However, weight-based monitoring offers several key advantages:
- Greater Accuracy
Weight measurement is not affected by material density shifts, temperature changes, or foam buildup.
- Improved Inventory Control
Real-time weight data ensures operators know exactly how much product is stored.
- Automation Capabilities
Weight indicators can trigger relays to start or stop filling processes automatically.
- Safety Protection
Upper and lower material limits can activate alarms to prevent overfilling or running tanks dry.
For this project, Brechbuhler Scales engineered a system centered around the B-TEK EZTM Series Tank-Mount Load Cell System.
Engineering the Right Foundation: Tank Support Legs vs. Flat-Bottom Tanks
One of the most important elements of this installation happened before the weighing equipment was even installed.
Brechbuhler Scales collaborated with:
- The local tank manufacturer
- The customer’s engineering team
- On-site project stakeholders
The recommendation?
Use tank support legs instead of flat-bottom tanks.
Why Are Tank Support Legs Important for Load Cell Systems?
Load cells measure force—in this case, the full weight of the tank and its contents. To accurately measure weight:
- The tank must rest on engineered support points
- The load must transfer directly through load cells
- Structural flex and uneven distribution must be minimized
Flat-bottom tanks typically distribute weight across a large surface area, making load cell integration more complex. By utilizing support legs, Brechbuhler Scales was able to integrate the B-TEK EZTM tank-mount load cell system cleanly and accurately beneath each tank.
This design ensures:
- Even load distribution
- Accurate weight readings
- Long-term structural stability
- Simplified installation and maintenance
The B-TEK EZTM Tank-Mount Load Cell System
The B-TEK EZTM series is engineered specifically for tank, hopper, and vessel weighing applications.
Key Benefits of the EZTM System:
- Designed for vertical tank installations
- Durable, industrial-grade load cells
- Corrosion-resistant components
- Reliable performance in indoor environments
- Ideal for process control applications
Each of the three 12,000-gallon tanks was equipped with the EZTM load cell system to capture continuous weight data.
But capturing the weight is only part of the solution.
The next stage involves intelligent monitoring and control.
Intelligent Control with the B-TEK T405S Weight Indicator
When Brechbuhler Scales technicians return to the site for final commissioning, they will complete installation of the B-TEK T405S Fully Programmable Weight Indicators.
These advanced digital indicators serve as the control center of the entire tank weighing system.
What Makes the T405S Ideal for Tank Monitoring?
The T405S is a fully programmable weight indicator capable of:
- Monitoring real-time tank weight
- Setting programmable high and low limits
- Triggering automated responses
- Integrating with external devices
For this installation, the indicators include internal:
(4) Relay 3-60 VDC @ 2A Output Option Cards
These relay outputs allow the system to control:
- Externally mounted LED stack lights
- Audible alarm systems
- Filling relays (start/stop automation)
- Acknowledge and alarm silence functions
How the System Will Function
Once fully installed and programmed, the system will:
- Continuously monitor the weight of material inside each tank
- Display real-time data on the T405S indicator
- Activate visual LED stack lights when limits are approached
- Trigger audible alarms when thresholds are exceeded
- Automatically stop filling operations when maximum capacity is reached
- Alert operators when levels drop below minimum thresholds
This automation prevents:
- Overfilling and potential environmental risks
- Material shortages
- Production downtime
- Manual monitoring errors
Why Brechbuhler Scales for Tank Weighing Systems?
Brechbuhler Scales provides more than equipment—they provide engineered weighing solutions.
In this Fort Wayne project, the team delivered:
- Early-stage design consultation
- Load cell system recommendations
- Collaboration with tank manufacturers
- On-site installation
- Programming and system integration
- Ongoing service support
With decades of expertise in industrial weighing systems—including truck scales, tank scales, hopper scales, and custom automation—Brechbuhler Scales ensures every project is designed for long-term reliability.
Frequently Asked Questions About Tank Weighing Systems
Can Brechbuhler Scales retrofit existing tanks with load cells?
Yes. Tank-mount load cell systems can often be integrated into existing tank structures, depending on design and support configuration.
Why choose load cell systems over ultrasonic or radar level sensors?
Load cells measure true weight, offering higher accuracy and consistency regardless of material density or buildup conditions.
Can tank weight systems integrate with alarms and automation?
Absolutely. As shown in this project, programmable weight indicators like the B-TEK T405S can control lights, alarms, and automated filling relays.
Are tank weighing systems suitable for hazardous materials?
System design depends on application requirements. Brechbuhler Scales can recommend appropriate components based on environment and material type.
A Scalable Solution for Growing Operations
This Fort Wayne, Indiana installation represents just the initial stage of the customer’s broader campus expansion.
By incorporating B-TEK EZTM tank-mount load cells and T405S programmable indicators, the customer now has:
- Accurate weight-based inventory monitoring
- Automated upper and lower limit control
- Enhanced safety features
- Scalable infrastructure for future expansion
Final Thoughts: Precision Matters in Material Storage
In modern manufacturing and industrial environments, guessing tank levels is no longer acceptable.
Weight-based monitoring through engineered tank scale systems provides:
- Real-time data
- Automated protection
- Improved efficiency
- Reduced operational risk
The Brechbuhler Scales Fort Wayne team continues to deliver innovative weighing solutions across Indiana and beyond—combining industry expertise with advanced B-TEK technology to support customers at every stage of their growth.
If your facility needs accurate tank inventory monitoring, automation integration, or load cell system installation, Brechbuhler Scales can design a solution tailored to your operation.
Looking to integrate tank weighing systems into your facility?
Contact Brechbuhler Scales to discuss your application and discover how precision weight-based monitoring can improve your operational performance.
