Custom Scale Systems and Controls


Progressive has developed hundreds of stand alone and networked scale and software systems to accomplish everything from data collection and bar code labeling to filling and automation. For your next project please give Progressive a call. We have the expertise to help you develop the right system for your needs.


Taco Bell Weight Capture System:

This system was designed for use in fast food establishments that want to keep track of weight data. Using a web interface, the client is able to control, menus and report on data collected from many extablishments. The rugged touch screen computer is restaurant hardened and the scale comes with a full flip down cover to protect it when not in use. This fast food check weighing system is also sound enabled giving the operator audio feedback whenever a transaction is recorded. Color coded screens flash to the operator to notify them of weight status for each transaction. A server application sends out email on a selectable basis notifying corporate and stores of their transaction averages and totals.

Bitterant Addition System:

Client: Anti-Freeze Manufacturer
System: Due to new goverment regulations, this very large Anti-Freeze manufacturer was forced to add bitterant to its products to keep it from tasting sweet which has led to accidental animal deaths. The product used to make the Anti-Freeze taste bitter is a very unfriendly substance. The manufacturer needed to handle it as little as possible. Progressive was commissioned to build a weight based automated bitterant filling and delivery system. The system worked so well that the batch master coined progressive the "True Rocket Scientists"

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Pharmacy Recipe Traceability System:

Client: Natures Plus
System: Natures Plus is a manufacturer of supplements.  Due to the stringent guidelines that the company imposes, Progressive was called to see if we could devise a system to talk to their SAP system as well as keep track of all items made and lot associations.  Progressive delivered a system comprised of touch screens , scales, bar code scanners and label printers. 

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Powder Coat Paint Recipe Traceability System:

Client: PPG
System: PPG is a manufacturer of powder coat paint.  Due to the complexities of color mixing and the impact it has on customer final products,  Progressive was called to see if we could devise a system to talk to their Oracle Databases as well as keep track of all items made and lot associations.  Progressive delivered a system comprised of touch screens , scales, bar code scanners and label printers. 

Pharmaceutical Scale and Balance System:
A division of Johnson and Johnson contacted Progressive to build a custom system to track batching for a pharmaceutical application. Phase 1 has already been installed and we are working on phase 2. Phase 1 involves multiple scales batching by both weight and volume using an ultrasonic measuring sensor. The measuring sensor was used as a load cell alternative to reduce the need for placing load cells at the bottom of every tank. Weight was calculated using volume and density.

Truck Scale Software System

H. Krevit manufacturing of North Haven CT, a manufacturer of bleaches and caustics, contacted Progressive for a truck scale system capable of bar code scanner integration and controls, weight to gallon conversion, data collection and assuring the right chemicals go in the right trucks. After installation of the truck scale and controls, Krevit saw a huge ROI. Now that the system is installed and running, the truck filling system saves as much as 1/2 hour per truck and is accurate to 2-3 gallons.

Caviar Processing System, Canada
A client contacted us in need of a Herring Fish Processing Software and Scale System. The time frame was very short, but Progressive came through. This processor pays workers by weight so the fish system needed to collect each weight as well as employee IDs. The system involved 3 networked scales and an SQL database. The main benefits are time savings, accuracy of data and integrated Crystal Reports.

Automated Bar Code Scanning Validation.

United States Surgical (Covidien) In order to make sure every suture is bar coded properly, United States Surgical Corporation called in Progressive Software Solutions. At 1/5th the cost of the nearest competitor, Progressive built an automated bar code scanning system. Using 2 Symbol bar code scanners, 1 photo eye and a logic controller, the system validates 2 bar codes against each other and rejects any invalid scans.

Counting and Labeling Scale System - The world's largest switch manufacturer contacted PSS to see if we could develop a networked counting scale that prints bar code labels to replace their pricey Intermec fixed station terminals. PSS got to work and developed a system that allows the client to connect to scales in Mexico, TX, CT, England and China all from an IT desktop at HQ. Scales can be programmed and monitored remotely all from the comfort of the IT director's office.


In Motion Check Weighing - Washington. A reseller contacted us asking if we could duplicate a program for a Rice Lake 920i that they had been buying elsewhere. PSS took the challenge and built the system. To the client's amazement, the system is far more accurate than the previous system making it easy for the reseller to beat out its competition. In some cases, the reseller is installing the in motion check weigher on competitive set ups that use the same scale indicator. Clients are thrilled with the accuracy increase.

Cross Dock Barcode System - Waterbury, CT. ITW, one of the largest manufacturing companies in the US, asked PSS to build them a cross dock wireless bar code system. The system uses Intermec wireless units to verify skidded boxes against an AS-400 database. As a result of scanning, master labels are produced for skids. To the client's amazement, the bar code system found errors on the first day of operation.


Automated Box Weight Filling System - Greenville , SC. A local scale dealer called in Progressive to pick up a project that the scale manufacturer did not complete to the client's satisfaction. Each box was filling to nearly 1/2 lb over target. A loss of nearly $300/hr. After consulting with the customer, Progressive devised a new program that would auto learn the product fill rate. Progressive completed the project within 3 days time and now fills exactly to target with 0 loss. Process includes automated box placement, automated filling, and automated box removal.

AS400 to Counting Scale - Through a scale distributor in the Northeast, PSS was able to assist in the winning of a contract for a beta site of 4 Rice Lake 920i programmable scales attached to their AS-400. Each scale pulls in job and average piece weight data, customer data and label format data. The system then controls a feeder and stops the feeder when a box is full. The system then prints a label and logs this info and sends the complete job info back to the AS-400 when complete.


Corn Flake Batching - A Massachusetts based scale company asked us to build a scale system for its client that spoke to a PC and pulled job data from an Access database and filled totes accordingly then printed a tote label. The 2 systems are currently running without issue.


Large Scale Batching Application - A North Texas Scale Company hired us to help sell a client on a new way of doing things as their old equipment was no longer supportable. We closed the deal together and delivered shortly thereafter. This system replaced 13 scale indicators and 1 programmable scale at the largest PVC pipe extruder in the US. The new Rice Lake 920i system now controls 16 scales and essentially the entire 24hr operation. The system processes approximately 150 batches per day and has not once failed.

RF Bar Code System - A McKinney Texas based manufacturer hired us to update their entire data collection system. After carefully researching the proper hardware and solution we gave a quotation to the manufacturer. Time passed and one day the phone rang and it had to be done "this week". We quickly did an Intermec site survey one day and installed the next. Within 2 days their system was up and operational.