The Future of Accuracy Automated Weighing Solutions by Brechbuhler Scales
Across today’s manufacturing, logistics, agricultural, and industrial markets, companies are expected to move faster, stay compliant, and operate with near-zero tolerance for error. Whether you’re running a processing plant in Dayton, a distribution center in Columbus, a steel operation in Canton, a recycling yard in Cincinnati, a chemical facility in Pittsburgh, or a bulk material site in Nitro, one reality is the same: automation is no longer a luxury — it’s a competitive necessity.
Brechbuhler Scales is leading that evolution with a full suite of automated weighing solutions designed to increase throughput, maximize accuracy, and streamline the flow of data across entire operations. From unattended truck scale kiosks to in-motion weighing, batching automation, data integration, and enterprise-level reporting, Brechbuhler combines precision-engineered hardware with ScaleSoft — our in-house weighing management software that powers the entire automation ecosystem.
If your facility is exploring modernization, digital transformation, or industry-specific compliance improvements, this deep dive breaks down how automated weighing is reshaping the scale industry across Ohio, Western Pennsylvania, West Virginia, Indiana, Kentucky, and the broader Midwest.
Why Automation Matters More Than Ever
- Workforce Shortages & Productivity Demands
Operations everywhere are stretched thin. Automation reduces repetitive manual tasks, minimizes human error, and allows skilled employees to focus on higher-value responsibilities.
- Increasing Compliance Requirements
Industries working under FDA, GMP, FSMA, ISO/IEC 17025, NIST Handbook 44, and USDA guidelines rely on precise, traceable measurement. Automated workflows reduce risk and preserve clean, audit-ready documentation.
- Integration Expectations
Modern facilities expect scales to communicate with:
- ERP systems
- MES platforms
- PLCs
- Inventory systems
- Dispatching and ticketing tools
- RFID/barcode identification
- Cloud-based analytics
Automation — powered by ScaleSoft — bridges all of these systems.
Unattended Truck Scale Systems & Kiosks (Powered by ScaleSoft)
This segment is one of the fastest-growing needs across the Midwest, and Brechbuhler Scales leads the market with fully integrated, hardware-to-software automation. Our unattended systems use ScaleSoft as the core engine, allowing facilities to operate efficiently around the clock with minimal staffing.
Key Capabilities
- Touchscreen driver kiosks fully integrated with ScaleSoft
• Automated ticket creation and digital recordkeeping
• RFID and barcode vehicle identification
• License plate capture & camera integration
• Traffic lights, gates & interlocks
• Secure customer/driver authentication
• Real-time weight recording with instant exports
• ERP, inventory & dispatch connectivity through ScaleSoft
This solution is transforming operations in:
- Quarries and aggregates (Columbus, Cambridge, Nitro)
- Grain and agricultural sites (Indiana & Western Ohio)
- Scrap and recycling operations (Pittsburgh, Cincinnati)
- Manufacturing and distribution centers (Dayton, Canton, Aliquippa)
By eliminating scale house bottlenecks, companies gain faster cycle times, reduced labor dependency, and precise digital documentation.
In-Motion Weighing & Conveyor Automation
For high-volume environments, stopping product to weigh it isn’t an option. Brechbuhler’s in-motion and conveyor-integrated systems bring together precision load cell technology and automated data capture to maintain accuracy at full production speed.
Common Applications
- Food & beverage processing
- Chemical and powder production
- Packaging and distribution
- Mining and aggregate conveyors
- Steel, metals & coil handling
- Agricultural processing
These solutions drastically reduce downtime while improving throughput — critical for plants across Dayton, Cincinnati, Columbus, Pittsburgh, and the Northeast Ohio industrial belt.
Automated Batching, Filling & Blending Systems (ScaleSoft-Driven)
Brechbuhler develops batching systems that integrate directly with ScaleSoft, allowing facilities to capture every detail of production with full digital transparency. Whether it’s liquids, powders, ingredients, or micro-components, ScaleSoft provides centralized recipe management and traceability.
Capabilities Include
- Multi-ingredient batching with programmable recipes
• Real-time data capture and scale-to-PLC communication
• Automated filling, dispensing & proportioning
• Checkweighing with reject logic
• Digital batch records stored within ScaleSoft
• Integration with MES/ERP for inventory & production reconciliation
These systems support chemical plants in Nitro, food processors around Dayton, pharmaceutical manufacturers in Western PA, and industrial facilities across the Midwest that require consistency, repeatability, and audit-ready documentation.
Data Integration, IoT & Industry 4.0 (Powered by ScaleSoft)
Automation isn’t just about weighing equipment — it’s about intelligent data control.
ScaleSoft acts as your facility’s central brain, connecting every scale, kiosk, sensor, PLC, and reporting channel into one unified system.
ScaleSoft Enables
- Real-time dashboards for local or multi-site operations
• IoT monitoring & predictive maintenance alerts
• Cloud or local storage options
• User permissions & secure access control
• API connectivity for ERP, MES & reporting tools
• Automated ticketing, batch logs & audit trails
• Remote diagnostics & troubleshooting
For companies operating across multiple branches — Canton, Dayton, Columbus, Cincinnati, Nitro, and Aliquippa — ScaleSoft ensures consistent documentation, uniform data standards, and enterprise visibility.
Automated Checkweighers & QC Systems (ScaleSoft Integrated)
For regulated industries, automated QC is essential. Brechbuhler’s checkweigher and QC solutions integrate with ScaleSoft to ensure every product is weighed, recorded, and verified automatically.
Capabilities
- Automated out-of-spec rejection
• Dynamic checkweighing at production speeds
• Batch/lot-level reporting
• Full traceability for FDA, GMP & ISO compliance
• Seamless QC recordkeeping inside ScaleSoft
This is mission-critical for packaging plants, food processors, and medical device manufacturers.
ScaleSoft: The Core of Brechbuhler’s Automation Ecosystem
Unlike generic third-party software, ScaleSoft is built specifically for industrial weighing — engineered for the speed, precision, and regulatory needs of Midwest operations.
Why ScaleSoft Matters
- Unified data across all sites and systems
• Precise, consistent measurement records
• ERP/MES/PLC integration flexibility
• Lower manual entry and error reduction
• Scalable for single-site or multi-site operations
• Stronger compliance and audit readiness
• Seamless integration with Brechbuhler hardware & kiosks
ScaleSoft is what makes Brechbuhler’s solutions truly turnkey — software, hardware, installation, calibration, and support from one trusted partner.
Why Midwest Companies Choose Brechbuhler for Automation
- Engineering Expertise
Over 100 years in the weighing industry means automation is rooted in proven measurement science — not guesswork.
- Full In-House Integration
Brechbuhler + B-TEK manufacturing + ScaleSoft = unmatched control from design to deployment.
- True Turnkey Solutions
Design → build → install → automate → calibrate → support.
- Local Support Across the Region
Technicians and automation specialists across OH, PA, and WV ensure fast, dependable service.
- Long-Term ROI
Automation reduces labor costs, increases throughput, improves accuracy, and positions companies for long-term operational success.
Final Thoughts: Automation Is the New Standard
Across the Midwest, companies are moving toward automated weighing because the ROI is no longer theoretical — it’s immediate. Faster cycle times. Stronger compliance. Better data. Reduced downtime. More accuracy. More profitability.
Whether you’re ready to upgrade to unattended truck scale automation with ScaleSoft, integrate batching with PLC-level controls, or modernize your QC processes, Brechbuhler Scales delivers automation that’s engineered for today and built for the future.
