Digital Upgrade Improves Manual Formulation

Improving Manual Formulation with a High-Resolution Digital Floor Scale

One of our partners in chemical manufacturing was using an older 10,000 pound floor scale certified to a 2 pound resolution to build precise chemical formulations. Many of the ingredient quantities in their recipes weighed less than the scale’s appropriate resolution. To work around this, operators tried to stretch the scale to read in 0.5 pound increments. Because this pushed the scale beyond its true capabilities, the displayed values did not reliably match what was actually being added. This led to inconsistent measurements and excessive waste from poorly formulated batches. The scale’s age and the extended resolution also caused frequent maintenance calls and mounting downtime, which made it difficult for operators to confidently formulate their product.

To help improve accuracy and reduce waste, the System Scale team reviewed how the scale was being used and recommended upgrading to a digital floor scale capable of operating at 0.2 pound process resolution in non-legal for trade applications. This higher resolution system provided the stability and repeatability needed for their manual formulation work without pushing equipment beyond its design limits.

After installation, our partner saw a significant drop in service calls, and their formulation process became more consistent. Operators could measure ingredients more accurately and with less frustration, which helped reduce waste and prevent off-spec batches. The improved resolution also supported a smoother and more efficient workflow for daily production.

The upgraded digital scale now gives our partner a reliable, long-term solution that improves accuracy, reduces downtime, and provides the precision needed to support consistent, high-quality manual formulation.