Tontrac’s Automated Weighbridge Management

Weighbridge agnostic – easily integrated, Tontrac’s automated cloud-based Site Access Control and Weighbridge Management Platform optimises complex weighbridge operations. In projects where it has been employed, the software simplifies and consolidates complex weighbridge processes. 

Presently, there is a boom in the mining sector. One of the ways this is noticeable is through an increase in haulier fleets handled at weighbridges on sites.

Ostensibly, the numbers are generally impressive – usually, more tonnage translates into high revenue. But mine management should ask themselves: How accurate is the data, and how efficient is the weighbridge management?

In weighbridge management, lapses are not uncommon, but they can be very costly. Clearly, this should be a matter of great concern to mine management as these lapses could translate to significant losses that are unaccounted for.

Tontrac’s Weighbridge Management Platform 

What is most heartening is that Tontrac’s cloud-based Site Access & Weighbridge Management Platform has proven the most effective solution to costly lapses in weighbridge management. This view is according to results from projects where the software is installed throughout South Africa.

This is what Tontrac’s CEO, William Butler, will convey to representatives of mining houses at the 2024 Investing in African Mining Indaba. He attributes the Tontrac Platform’s efficacy to the ease of integration and the vast array of benefits it offers.

Ease of integration 

Typically, integration is a challenge with different software packages for different mining functions. However, Tontrac’s weighbridge software is agnostic, meaning it can integrate with any weighbridge.

Butler highlights three core aspects of Tontrac’s integration:

“Firstly, the weight generated by the load cells is passed through the indicator to the weighbridge PC and read by the Tontrac software. No human capturing is required.

“Secondly, Tontrac has a built-in Site Access Control that is integrated with the weighbridge function so that only pre-authorised vehicles are allowed into the site and onto the weighbridge. Unauthorised vehicles are blocked from entering the site by the System.

“Thirdly, Tontrac incorporates a seal matching system where Tontrac-specific seals are recorded in the system and affixed to the trucks before dispatch. The seals are scanned on the receiving end and matched to the dispatch seals to confirm the load has not been tampered with. In addition, the system automatically compares tonnes dispatched with tonnes received to ensure what was dispatched has in fact arrived at the receiving site. Discrepancies are highlighted automatically for further investigation.”

Vast array of benefits 

The Platform offers a vast array of benefits, specifically: assisted haulier fleet management per order, site access control and traffic management, weighbridge automation, inter-site reconciliation and 24/7 support – both on and off-site.

Through these benefits, Tontrac’s weighbridge automation allows mines to optimise weighbridge management by simplifying and consolidating complex tasks, registering gains in enhanced security, regulatory compliance, and improved productivity.

1. Assisted Haulier Fleet Management per Order 

• Hauliers, their drivers, and vehicles are pre-registered in the Cloud.
• Orders to move the product from site A to site B are created in the Cloud.
• Approved Haulier Fleet details are loaded onto the Order.
• Order progress is automatically monitored to completion and the information is made available on the Tontrac Mobile App in real time.
• The system monitors departure and arrival times of “Vehicles en route” between sites, flagging overdue vehicles, for investigation by site security.

2. Site Access Control and Traffic Management

• Pre-authorisation of vehicles and drivers is done for each order before they arrive on site. (Security)
• Only pre-authorised vehicles are allowed on site. (Security)
• The system decides to allow a vehicle on site, not a person. (Security)
• Automated checking of Vehicle and Driver Inductions at the Main Gate. (Regulatory compliance)
•  Limits the maximum weight of vehicles leaving the site to regulatory maximum. (Regulatory compliance)
• Tracks vehicle movement on site between the main gate, the weighbridge, and the stockpile. (Security)
• Site turnaround time management
• Inter-site turnaround time management

3. Weighbridge Automation 

•  Automates the capturing of weights on the weighbridge (Productivity and Security)
•  Automates the printing of weighbridge tickets on the weighbridge (Productivity and Security)

4. Inter-Site Recons 

•  Automates comparison of data generated on the dispatch weighbridge with data generated on the receiving weighbridge to ensure what left the dispatch site arrived at the receiving site. (security)
•  Tontrac Seals are issued to the haulier/truck driver and recorded in the system and printed on the weighbridge ticket.
•  Tontrac seals and trailer registration numbers are compared between the dispatch site and the receiving site to identify tampered-with trucks.

5. 24/7 Support 

• Control Room Operators remotely monitor and support on-site activities in real-time.
• Field Service Technicians are available on-site to resolve any automated equipment failure within minutes to maximise production uptime.  

Uniqueness 

The vast array of benefits of the Tontrac Platform is unique among comparable solutions.“Thus far, no comparable platform exists. Competitor products focus on either weighbridge automation or site access control, not both, and the data is exported to thumb drives.

In contrast, with the Tontrac Platform, the data is available in real-time on any PC or mobile device, anywhere in the world. For example, an executive in London can monitor production on a mine in Africa on his mobile phone, updated every few minutes. There is a real-time relay of production as well as fleet data and traffic management data to the mine hauliers to manage operations between sites. The system has real-time integration of weighbridge data between different sites via automated ticket reconciliation,” says Butler.  

Worthwhile investment 

For mining companies, incorporating Tontrac in their weighbridge management is a worthwhile investment. Mainly, the cutting-edge software pays off immensely, through the following takeaways:

• Up to a fivefold productivity increase on the weighbridge, compared to traditional systems, due to weighbridge automation. No matter how big a stockpile, it can only be turned into cash once the product has gone over a certified weighbridge. The faster this can happen, the faster cash is generated. This benefit alone can result in the investment paying for itself.
• Enhanced Cloud Based site access controls make it significantly harder for organised crime syndicates to get onto the site
• Maximum weight settings on the weighbridge software can prevent overweight trucks from illegally leaving the site.
• Cash Flow acceleration due to ticket reconciliation happening automatically in the system in real-time thus preventing a delay due to manual reconciliations in traditional systems, which delays invoicing.
• Cost reduction as weighbridge staff can be redeployed elsewhere.
• Data is captured directly from the weighbridge, with no human intervention, eliminating manual entry errors.
• Real-time weighbridge data from multiple sites is visible in real-time on mobile apps and in the cloud.