Practical Guide for Industrial Scales: 3 Critical Wear Parts & Fast Replenishment
In factories, warehouses and production lines, industrial scales work tirelessly to track materials, maintain product quality and ensure smooth operations. Even the most reliable industrial balances can be brought to a halt when small wear components fail. Sensors, rollers and display screens are often the cause of weighing task halts, which slows down production and damages your bottom line.
This guide is intended to assist you to learn how to identify early signs of wear on these three key parts, store spare parts correctly and minimize downtime costs for your industrial scales.
3 Critical Wear Parts of Industrial Scales
To function properly, industrial scales rely on certain components, and these three parts are most likely to wear out over time. Knowing how industrial scales work, how to store spares and what to look out for will help you keep them running efficiently.
Sensors
Sensors are at the core of every industrial scale. They convert weight into electrical signals, so they directly determine the accuracy of weighing data. If a sensor malfunctions, your industrial scale will not provide accurate readings.
To identify a failed sensor, watch for three key signs: fluctuating weights, a “sensor-error” code displayed on your industrial scale, or a sensor with a rusted surface and loose wires.
For spare part management, follow these tips: always use OEM (original equipment manufacturer) parts, as they fit better and last longer; store spares in cool, dry environments to prevent damage or rust; keep 2 spares for every 1 industrial scale, following a 1:2 ratio.
Rollers
On many industrial scales, rollers (also called “support rollers”) support conveyor belts or drums. They reduce friction and allow materials to be moved smoothly across the scale. Without rollers, your industrial scale will not be able to feed or transport products, which can bring work to a complete halt.
A failing roller typically shows these signs: loud noises such as squeaking and grinding, a worn-out surface, a peeling rubber coating, or a hot feel when touched.
When storing spare rollers, separate them by material—keep rubber rollers apart from metal ones. If your workplace is dusty or damp, stock extra rollers, as these conditions speed up wear. Follow a 1:5 ratio, keeping 1 spare for every 5 rollers in use.
Display Screens
Display screens serve as your link to industrial scales. They show real-time weight data, error codes and settings. Without a functioning screen, you cannot resolve minor problems or read important information related to the scale’s operation.
A failing display often presents one or more of these issues: a black or dim screen, jumbled numbers or symbols, unresponsive buttons, or laggy performance on touchscreen models.
For spare display screens, keep 1 spare per industrial scale—this 1:1 ratio is necessary because screens are hard to work without. Ensure spares match your scale’s connection type, such as USB, HDMI or proprietary plugs. Apply a protective layer to spare screens to avoid scratches during storage.
Fast Replenishment for Wear Parts
Even with a large inventory of spare parts, you will eventually need to replenish them. These strategies will help you replenish quickly and ensure your industrial scales are never out of service for long.
Classified Inventory System
An organized inventory system helps you avoid running out of critical parts for industrial scales and makes it easier to find spares when they are needed.
Start by labeling parts according to their type. For sensors, mark the model number and accuracy level; for rollers, note the size and material—an example label could be “Roller – Rubber – 10cm Diameter”; for display screens, indicate the connection type. Next, set warning thresholds to trigger replenishment. For instance, order new rollers if you have fewer than 5 spares for every 5 industrial scales, and order new screens if the number of spares is less than the number of industrial scales in use.
Tiered Supplier Collaboration
Having multiple suppliers ensures you can obtain parts even if one supplier is out of stock, which is vital to keeping industrial scales running continuously.
When choosing a core supplier, check that it meets three key criteria: it should be OEM-authorized to sell genuine parts for industrial scales, offer next-day delivery for emergency situations, and provide technical support such as help with sensor installation or troubleshooting. Additionally, select at least one backup supplier—this “Plan B” should cover parts that the core supplier may lack. If your workplace is in a remote area, ensure the backup supplier can deliver to that location. This way, you can get parts quickly even if the core supplier is out of critical sensors or rollers.
Maintenance to Prolong Wear Part Life
Caring for wear parts not only prolongs their lifespan but also saves you time and money by reducing the frequency of replacements.
Sensor Maintenance
For daily care of sensors, wipe the surface with a clean, dry cloth every day to remove dust and debris. Once a week, use a neutral cleaner for a deep clean to keep the sensor in good condition.
For regular maintenance, calibrate the sensor once a month—if you use a high-accuracy industrial scale, calibrate it every two weeks instead. Also, check the sensor’s connecting wires regularly for oxidation, which can affect performance.
Roller Maintenance
In daily care for rollers, apply lithium-based lubricant every two weeks to keep the bearings running smoothly. Once a month, disassemble the bearings to remove old grease and replace it with new grease. If you notice stuck material on the roller surface, scrape it off immediately to prevent uneven wear.
For regular checks, measure the bearing temperature once a week. If the temperature exceeds 40°C, stop using the roller and investigate the cause of the overheating. Replace rollers as soon as wear reaches 2mm, as worn rollers can cause conveyor jams on industrial scales.
Display Screen Maintenance
For daily care of display screens, install a tempered glass protector to prevent cracks from accidental bumps. If your workplace is humid, use a small blower to remove moisture from the screen, as moisture can damage internal components.
For regular maintenance, especially for smart screens with built-in software, update the system and clear the cache every three months. This helps keep the screen responsive and ensures it functions properly.
Conclusion
Industrial scales depend on three key wear parts to stay operational: sensors for accuracy, rollers for smooth movement, and display screens for data access. By learning to recognize early signs of wear on these parts and storing spares in the correct ratios, you can keep your industrial scales running smoothly.
This guide provides actionable tools to help you manage industrial scale maintenance and spare parts. Start by assessing your current spare parts inventory to identify gaps. Then, set up a classified inventory system to track parts effectively. Finally, partner with tiered suppliers to ensure fast replenishment. Taking these steps will save you from costly production delays in the future and ensure the reliable operation of your industrial scales.
