Case Studies
Real results in some of the most demanding and complex rail operations.
+4 Tonnes of Ore in Every Railcar
At one of the world's largest iron ore mines, each railcar left about 4 tonnes below safe capacity, and unevenly loaded, raising risk on the track. MASSA turned loading into precision.
- Challenge
Railcars underloaded by ~4 t and unevenly distributed: less ore shipped per trip and derailment risk.
- Solution
Silo loading with TOP-OFF and intermediate dynamic scales that report the weight across the 4 quadrants to the operator in just 9 seconds, completing the load with precision and even distribution.
- Result
8 Dynamic Rail Scales (SIMM S-02 and S-05, IP68). Even load, more safety and far more value shipped per trip.
Weighing Without Stopping Rumo's Flow
At Rumo's Rondonópolis multimodal terminal, weighing couldn't disrupt the operation. MASSA weighs coupled trains, in motion, and still allows maneuvers.
- Challenge
Weigh inbound (fertilizer) and outbound (grain) without interrupting the continuous rail flow or requiring weighing maneuvers.
- Solution
Dynamic Scales integrated into the process: continuous weighing inbound, before the hopper, and outbound, tare after cleaning and gross after loading.
- Result
6 scales (4 BFD SIMM S-02, IP68 for harsh conditions). No more time lost in maneuvers, less fuel and fewer emissions.
Zero Error Across 24,480 Railcars per Month
Six scales that didn't communicate and a faulty axle count caused incomplete weighings. MASSA redesigned the system, mechanics, electronics and software, and drove the error rate to zero.
- Challenge
6 scales with no communication (2 inbound lines, 4 outbound) and inductive sensors generating false positives, closing weighings incompletely.
- Solution
Removal of the 16 inductive sensors, a new rugged IP+ structure, DUAL electronics and ADX technology, which measures the individual deformation of each strain gauge to identify each wheel's entry and exit. SIMMSOFT7 software with a SQL Server database and MASSA's own CPU.
- Result
6 BFD class 0.5 (2 tare + 4 gross), IP+ rails, IP68. Incorrect weighings driven to zero, with 99.5% accuracy per railcar and 99.75% per train.
No risk to the client: MASSA ran the project at no additional cost until the terminal confirmed acceptance against the agreed metrics.
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