Truck terminal automation

The lot is complete before the barrier lifts.

Bags are counted on the conveyor as they load, the running count is verified against the dispatch lot and cross-checked on weight, and the bay barrier releases the truck only when the lot is proven complete — printing a dispatch slip from measured data, not from a number in someone’s head. Deployed at cement and fertilizer dispatch gates.

Gate to slip: bags counted & weighed → lot verified complete → barrier lifts → dispatch slip printed — every load, on the record.

No more “how many bags left on that truck?” — the count is measured, the weight agrees, and the gate proves it before the vehicle moves.

The dispatch gate, instrumented end to end

Counting, weighing and the barrier are tied together, so a truck can only leave on a lot that has been measured — and every load leaves a record.

CountBags counted on the conveyor by hybrid sensing

VerifyRunning count checked against the dispatch lot

WeighCross-checked on load cell / weighbridge net weight

GateBay barrier releases only on a complete lot

SlipDispatch slip printed from measured data

DashboardLive bay status, throughput & history to cloud

What it fixes

🔢

Counted by eye

At loading speed a hand-count is unreliable. Hybrid sensing counts every bag onto the truck, accurately, at line speed.

⚖

No evidence in a dispute

When the customer disputes the quantity received, there was nothing to show. Now the count and the net weight agree — and it is on record.

🚪

Barrier opened on a shout

The gate used to open on someone’s word. Now it releases only when the lot is proven complete — short loads cannot leave.

📋

Slip written after the fact

The dispatch slip was filled in from a number nobody could verify. Now it prints from measured data at the moment of release.

Where it runs

Cement & building materialsFertilizerChemicals Food & FMCG baggingSugar & grainWarehousing & logistics Ports & terminalsAny bagged-goods dispatch

In service: cement producers, from the bagging line to the dispatch gate. Truck Terminal is also available as a module of the Production Genie integrated platform.

How it works

Truck in → verified lot → gate out

The same sequence you just watched in the animation, step by step:

Truck arrives at the bay
The vehicle is identified at the loading bay and linked to its dispatch order and lot size. The bay status board shows LOADING.
Bags counted on the conveyor
As bags load, they are counted on the conveyor by hybrid sensing — a vision camera and an IR break-beam together — so the count holds at loading speed and no bag is missed or double-counted.
Hybrid count
Count verified against the lot
The running count is checked live against the dispatch lot for that truck — the board shows how many of the target have loaded, and a short pack is flagged on the spot.
Cross-checked on weight
The count is cross-checked against net weight from a load cell / weighbridge — count and weight must agree, catching a wrong bag weight or a miscount either way.
Count × weight agree
Lot complete → barrier releases
Only when the lot is proven complete does the bay barrier release the vehicle. A short or over load holds the gate — the truck cannot leave on an unverified count.
Gate on complete lot
Dispatch slip printed
A dispatch slip is printed from the measured data — count, net weight, lot and time — and the load is logged to the live dashboard and cloud.
Slip from measured data

⚖

Two independent proofs. Counting can drift and weighing can drift — but they rarely drift the same way. Making the count and the net weight agree before the gate opens is what turns “we think it’s right” into a dispatch you can defend.

Hardware

Sensing, weighing and gate control

Rugged, dusty-environment hardware — and, because KVAR builds its own displays and controllers, the bay board and the edge box are ours too.

HYBRID BAG COUNTERphoto to follow

Vision camera + IR break-beam counter

Vision camera with edge controller counts bags on the conveyor
IR break-beam confirms each bag — hybrid sensing for accuracy at speed
Rejects double-counts and gaps; holds up in cement dust
Mounts over the existing loading conveyor

LOAD CELL / WEIGHBRIDGEphoto to follow

Weight verification

Load cell / weighbridge gives net dispatched weight
Cross-checked against the bag count in real time
Catches a wrong bag weight or a miscount

BAY CAMERA + BARRIERphoto to follow

Bay camera & barrier control

Truck-bay camera and boom-barrier control
Barrier interlocked to the lot-complete signal
Releases the vehicle only on a verified lot

BAY STATUS DISPLAYKVAR-built board

Bay status display & edge controller

Large KVAR display shows count, target and bay status
Edge controller ties camera, beam, weigh and barrier together
Runs on the local network with cloud sync

Software

The bay dashboard and the dispatch record

One screen for the bay, one record for every load — both fed automatically by the count, the weight and the gate.

📻

Live bay dashboard

Every bay, the truck in it, count vs target and status at a glance — loading, complete or held.

⚖

Count × weight cross-check

Bag count and net weight reconciled in real time; a mismatch is flagged before the gate opens.

🚪

Lot-complete & barrier logic

The rule that releases the barrier only on a verified, complete lot — short and over loads held.

🖨

Dispatch slip generation

Prints the slip from measured data — count, net weight, lot, truck and time.

☁

Cloud sync

Every load synced to the cloud — live from anywhere, and safe off-site.

📊

Throughput & reports

Trucks dispatched, bags & tonnes loaded, loading time per truck, short-load exceptions — daily and by bay.

Reports, in full. Trucks dispatched and lots completed, bags and net tonnes loaded, count-vs-weight variance, loading time and bay turnaround, and short / over-load exceptions — exportable to Excel and PDF, and rolled up across bays and sites in Premium. Integrates with the plant ERP / dispatch system where an interface is available.

Editions & ROI

Basic, Advanced, Premium

Start with a counted, displayed bay; add weight cross-check and gate interlock; scale to multi-bay dispatch with ERP integration — hardware and software together.

Basic

Count & display

Hybrid bag counting on the conveyor with a bay status display and count-vs-lot on screen, plus a daily dispatch count. Accurate counting from day one.

Advanced

Weigh, gate & slip

Adds weight cross-check, lot-complete barrier interlock, dispatch-slip printing, the live bay dashboard and the full report set.

Premium

Multi-bay & connect

Adds multi-bay dashboards, cloud roll-up across sites, ERP / dispatch-system integration and exception analytics.

Capability	Basic	Advanced	Premium
Hybrid bag counting (camera + beam)	✓	✓	✓
Bay status display & count vs lot	✓	✓	✓
Weight cross-check	OPT	✓	✓
Lot-complete barrier interlock	—	✓	✓
Dispatch-slip printing	—	✓	✓
Live bay dashboard	OPT	✓	✓
Cloud sync	OPT	✓	✓
Multi-bay / multi-site roll-up	—	—	✓
ERP / dispatch-system integration	—	OPT	✓

✓ included OPT optional add-on — not in this edition. ERP interface subject to the plant system offering one.

Return on investment

✓

No more short-load disputes — count and weight agree, on record, so a disputed quantity is settled with proof.

✓

No giveaway — over-loading a truck is caught the same way a short load is; you dispatch exactly the lot.

✓

Faster turnaround — the gate clears a verified lot automatically, no manual tally at the bay.

✓

Every load traceable — count, weight, lot and time on the dispatch record and in the cloud.

✓

Throughput visibility — trucks, bags and tonnes per bay and per shift, to plan the gate.

✓

One supplier — sensing, weighing, display, gate and software from one team.

From a count in someone’s head — to a lot measured, weighed and proven before the truck moves.

The Truck Terminal solution is configured to the bay — conveyor, sensing, weighing, barrier and dispatch rules are set to the plant. Hardware and editions are matched to the requirement, and a firm quotation is prepared against it. Truck Terminal is also available as a module of the Production Genie integrated platform. Product photographs to follow. Contact KVAR Technologies for a survey of your dispatch bays and a sized proposal.