Stricter enforcement of load cell inspections in 2026: Jowic Elteknik and Beckhoff secure industrial load cells

The most common faults on load cells and industrial scales

The view on machine safety is undergoing a major shift. Previously, many companies could rely on experience and proven old weighing systems that felt like they worked well enough in everyday operations. But with stricter enforcement of existing regulations, that is no longer enough, and safety functions must now be risk-assessed, quantified, and documented.

During a control inspection, older machines and heavy applications (such as cranes, silos, and conveyor belts) quickly fail if the systems cannot prove their reliability. The most common hidden deficiencies exposed are:

• Lack of redundancy: Older systems are often single-channel. If a cable breaks or a load cell wears out, it is not noticed until a critical situation arises. For higher-risk applications, redundant (two-channel) signal paths are required today, which continuously compare measurement values with each other.

• Outdated indirect measurement: Estimating weight by measuring the pressure in a hydraulic cylinder or the power consumption of an electric motor lacks the precision and reliability required when the measurement is to function as a pure safety function.

• Mechanical wear: Load cells that have become misaligned, damaged by corrosion, or where mechanical stresses in the surrounding pipelines make the measurement value unstable.

Failed inspections can lead to formal citations or an immediate stop

The consequences of failing the annual inspection are significant for production. If a system is rejected, it means that the plant does not meet current legal requirements. Depending on the severity of the fault, failure can result in anything from a formal citation to, in the worst-case scenario, an immediate operation ban on the equipment.

In practice, this means that for severe deficiencies, the business is forced to stop production or the specific machine until the fault has been rectified and verified. Building in safety too late often leads to expensive reworks and long lead times. Furthermore, continuing to run with a rejected function is against the rules and can lead to significant penalty fees or an immediate operation ban during an inspection.

A unified weighing system from Beckhoff clears up the chaos

Another major challenge for the industry is the enormous variety of different old computer systems, software, and manufacturers scattered across factories. This makes maintenance and spare parts management extremely difficult to handle. According to EN ISO 13849, it is actually the entirety, from sensor to control system, that determines whether a system can be approved.

To solve this problem from scratch, our team at Jowic Elteknik is currently developing a completely new, unified weighing system. Instead of a lot of scattered old solutions, the technology is replaced with a robust control system from Beckhoff. By linking the load cells together with a common, modern safety brain, an unbroken and approved safety chain is created.

The system is also equipped with an intuitive web interface. This allows the customer to very easily monitor their operations in real-time, get full traceability, and ensure that the plant is legal, efficient, and safe ahead of the annual inspection.

Want to know more? Contact us and let's talk.