Precision at the Heart of Modern Quarrying
First published in the December 2025 issue of Quarry Management
Driving efficiency in quarrying through intelligent belt weighing automation
The quarrying industry continues to evolve under increasing demands for higher productivity, tighter environmental control, and consistent material quality. In this competitive and highly regulated environment, automation and accurate process control have become essential tools for success.
Procon Engineering, a division of NOV, are renowned for their advanced belt weighing and load-measurement solutions. Their systems are engineered not only to deliver reliable weighing performance, but also to integrate seamlessly into modern automation platforms – allowing quarry operators to gain real-time visibility, control, and traceability across their entire material-handling process.
The role of belt weighing in quarry operations
Belt weighing systems – or conveyor belt scales – are fundamental to quarry operations. They provide continuous, dynamic measurement of bulk materials such as aggregates, sand, and minerals as they move through the production line. Accurate belt weighing allows operators to:
Monitor production output in real time
Optimize plant efficiency by balancing material flow between crushing, screening, and stockpiling
Reduce waste and downtime through early detection of process deviations
Maintain regulatory compliance by ensuring accurate load data for billing and reporting.
However, in quarry environments characterized by dust, vibration, and variable loading conditions, achieving and maintaining weighing accuracy is far from straightforward, which is where Procon’s expertise can make the difference.
Bespoke engineering for real-world conditions
Unlike many off-the-shelf systems, Procon Engineering take a bespoke-to-standard approach. Every belt weighing installation is engineered to suit the specific mechanical layout, belt type, material characteristics, and environmental conditions of the quarry.
‘Our philosophy is simple,’ explained a Procon engineering specialist. ‘We design each system around the application, not the other way around. Whether a customer needs a simple single-idler solution or a fully automated multi-belt system with integrated data logging and control, we tailor the system to achieve maximum accuracy and reliability.’
This approach ensures that every weighing solution – from the load-cell designs to solutions utilizing Procon’s resometric measurement configuration – is optimized for long-term performance and stability.
Load-cell and resometric measurement technology
At the heart of every Procon belt weigher lies precision load-cell technology, developed and manufactured to exacting standards. Load-cells are responsible for converting the mechanical load of the material on the conveyor into an electrical signal that can be processed and calibrated.
Procon offers both strain-gauge and resometric measurement technologies, selected according to the demands of the application:
Strain-gauge load-cells: These are the industry standard for robust and accurate performance. Ideal for most quarrying applications, they provide excellent stability and repeatability under heavy loads and harsh operating conditions
Resometric measurement: This advanced technology is particularly suited to installations where environmental factors such as vibration, temperature change, or mechanical distortion could affect traditional load-cell accuracy. By measuring changes in the resonant frequency of the load element rather than strain, resometric sensors deliver exceptional long-term stability and minimal drift – reducing the need for recalibration.
Both technologies are supported by Procon’s in-house calibration and testing facilities, ensuring every system meets stringent performance criteria before leaving the factory.
Integrating automation and control
Modern quarry operations rely on automation not only for process efficiency, but also for data integration and traceability. Procon’s belt weighing systems are designed with automation and connectivity in mind.
Each system can be interfaced with:
SCADA and PLC platforms for process control and plant management
Data-acquisition systems for performance monitoring and remote diagnostics.
This integration allows quarry managers to visualize production data in real time, compare outputs across multiple conveyors, and respond rapidly to changing operational demands. The result is a more efficient, consistent, and profitable process.
From quarry to customer: Data that drives decisions
The move toward digitalization in quarrying means that real-time process data has become as valuable as the material itself. Accurate belt weighing information allows:
Production balancing: ensuring crushers, screens, and conveyors operate in harmony
Maintenance planning: identifying performance anomalies before they become costly breakdowns
Stock control: maintaining accurate inventory records and reducing overloading risks
Quality assurance: verifying material consistency and grading throughout the production cycle.
With accurate measurement from belt scales with intelligent process control instrumentation, operators can make data-driven decisions that improve yield and efficiency.
Engineered for longevity and reliability
Quarry environments demand equipment that can withstand continuous operation in tough conditions. Belt weighers must be designed and built to last, with rugged frames, corrosion-resistant finishes, and industrial-grade electronics. Each Procon installation is backed by:
Comprehensive service support, including commissioning, calibration, and maintenance
Remote diagnostics and software updates where applicable
Spare parts and upgrade options to extend system life and enhance performance over time.
This lifecycle support ensures that customers enjoy consistent weighing accuracy and uptime, maximizing their return on investment.
Applications across the quarrying spectrum
Procon’s weighing and automation systems are used across the full spectrum of quarry operations, including:
Primary extraction: monitoring material conveyed from the face or crusher
Screening and sorting: tracking material flow between grades
Blending and batching: ensuring correct mix ratios
Stockpiling and load-out: providing precise loading data for dispatch and invoicing.
Each application benefits from the company’s deep engineering experience and ability to deliver solutions that fit seamlessly within existing plant layouts and control architectures.
Commitment to continuous innovation
As part of NOV, Procon Engineering have access to a global network of research, design, and manufacturing expertise. This allows continuous innovation in weighing, control, and automation technologies – keeping Procon at the forefront of industrial process measurement.
Future developments will focus on expanding digital connectivity, enhancing predictive maintenance through data analytics, and integrating with next-generation automation systems that align with Industry 4.0 standards.
Partnering with the quarrying industry
Procon Engineering have built their reputation on partnership. By working closely with quarry operators, plant designers, and equipment manufacturers, the company ensures each system meets operational goals for accuracy, efficiency, and compliance.
This collaborative approach extends beyond installation, through training, support, and system optimization, ensuring the technology continues to deliver value throughout its lifecycle.
Intelligent weighing for a smarter quarry
Automation is no longer a luxury in quarrying; it is a necessity. As the industry continues to pursue efficiency, sustainability, and profitability, the role of intelligent weighing technology will only grow in importance.
Engineered belt weighing solutions – with their combination of robust engineering, precision measurement, and advanced automation – provide the foundation for smarter, more connected quarry operations. Each system represents not just a weighing device, but a bridge between material flow and data-driven control.
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