Control & Automation Load Cells – Precision Weighing Sensors for Process Integration
Load cells for control and automation applications are the primary sensing element in any process weighing system — converting the weight of a vessel, platform, hopper, or conveyor into a precise electrical signal that feeds a digital weight transmitter, PLC input, or process controller. Unlike load cells used in standalone weighing instruments, process load cells are designed for permanent installation under continuous static or dynamic loads, in environments that may be wet, corrosive, high-temperature, or classified as hazardous — and they must maintain accuracy and stability over years of uninterrupted operation without drift or degradation.
Our range covers the load cell types most commonly used in process weighing and automation: compression canister load cells for tank, silo, and vessel base installations; tension load cells for suspended hoppers, reactors, and bins; shear beam load cells for platform and conveyor weighing; and single point load cells for compact bench and in-line weighing applications. Capacities range from a few hundred kilograms to 100 tonnes per cell, with multi-cell systems capable of weighing process vessels of virtually any size. All models are available with IP67 or IP68 protection as standard, and ATEX-certified variants are available throughout the range for Zone 1, Zone 2, Zone 21, and Zone 22 hazardous area installations.
Selecting the correct load cell for a process automation application requires careful consideration of capacity, mounting arrangement, environmental conditions, communication requirements, and long-term stability. Our technical team can advise on load cell type, capacity calculation, protection rating, mounting module compatibility, and integration with digital weight transmitters and PLCs to ensure your system delivers accurate, reliable process data from commissioning through to the end of its service life.
Load Cell Types Available
- Compression canister load cells — for base-supported tank, silo, and vessel process weighing installations
- Tension load cells — for suspended hopper, reactor, and bin weighing in process environments
- Shear beam load cells — for platform scales, conveyor weighing, and lower-capacity process installations
- Single point load cells — for compact bench, in-line, and checkweighing automation applications
- ATEX-certified load cells — for Zone 1, 2, 21, and 22 hazardous area process installations
Key Features
- IP67 and IP68 protection as standard for outdoor, washdown, and immersion process environments
- High long-term stability and low creep for continuous static load process applications
- Stainless steel construction for hygienic, corrosive, and food-grade process environments
- ATEX-certified models for Zone 1, 2, 21, and 22 hazardous area installations
- Wide capacity range — from 500 kg to 100 t per cell for process vessels of all sizes
- Compatible with standard mounting modules, equalisation junction boxes, and digital weight transmitters
- UKAS-traceable calibration certificates available on request
Common Applications
- Tank and silo base weighing for PLC-integrated inventory and process control
- Reactor and process vessel weighing in chemical and pharmaceutical manufacturing
- Automated batching and dosing — weight-triggered valve and pump control
- Conveyor and in-motion weighing integrated with production line automation
- Hopper and bin weighing for loss-in-weight and gain-in-weight process control
- Checkweighing and fill weight verification on automated packaging lines
- Hazardous area process weighing in ATEX-classified chemical and pharmaceutical plants
All load cells are sourced from leading manufacturers and are available with UKAS-traceable calibration certificates on request. Contact our technical team for advice on load cell selection, capacity calculation, and integration with your process control system.
Frequently Asked Questions
What load cell type is best for process weighing and automation?
The correct type depends on your application. Compression canister load cells are the standard choice for base-supported tanks, silos, and vessels — they are robust, high-capacity, and designed for long-term static load applications. Tension load cells are used where the vessel is suspended rather than base-supported. Shear beam load cells are widely used in platform and conveyor weighing where a low-profile installation is required. Single point load cells suit compact in-line and bench weighing automation. Contact our team with your vessel type, capacity, and mounting arrangement for a specific recommendation.
How do I calculate the load cell capacity I need for a process vessel?
The total system capacity must cover the maximum weight of the vessel when full, including the tare weight of the vessel structure, agitator, pipework connections, and any other permanently attached components. For a three or four-cell system, divide the total maximum load by the number of cells, then add a safety margin of 25–50% to allow for dynamic forces, uneven load distribution, and overload protection. Contact our technical team with your vessel dimensions, tare weight, and maximum fill capacity for a capacity recommendation and load cell selection advice.
What IP protection rating do I need for a process environment?
For indoor process environments with occasional washdown, IP65 (dust-tight and water jet resistant) is typically sufficient. For outdoor installations, pits, or areas subject to flooding, IP67 (temporary immersion to 1 m) is the minimum recommended rating, and IP68 (continuous immersion) is preferred for the most exposed locations. For food, dairy, pharmaceutical, and chemical washdown environments, IP68 stainless steel load cells are the appropriate choice. All load cells in our process range meet IP67 or IP68 as standard — contact us to confirm the rating for a specific model.
How does a process load cell connect to a PLC?
A process load cell outputs a millivolt signal (mV/V) that cannot be read directly by a PLC input card. A digital weight transmitter is used to convert this signal into a PLC-compatible output — typically 4–20 mA analogue, Modbus RTU, Profibus DP, or EtherNet/IP. In multi-cell systems, the load cell signals are first combined and balanced in an equalisation junction box before being passed to the transmitter. The transmitter then delivers a single, accurate weight value to the PLC for use in the control programme. Our technical team can advise on the complete signal chain from load cell to PLC for your specific application.
Are ATEX-certified load cells available for hazardous area process installations?
Yes. We supply ATEX-certified compression and tension load cells approved for Zone 1, Zone 2 (gas and vapour hazards) and Zone 21, Zone 22 (combustible dust hazards). These are required for process weighing in chemical plants, pharmaceutical facilities, fuel storage, and grain handling environments where flammable atmospheres may be present. Contact our technical team before specifying equipment to confirm the correct zone classification, equipment category, and gas group for your installation.
