Weight-based material tracking from blast to invoice, with the hardware integration that makes the numbers trustworthy.
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Quarries and stone crusher units need ERP that measures material by weight through conversion rather than as countable stock, and that captures weighbridge, beltscale and vehicle data directly. Without hardware integration, dispatch records depend on manual slips, which is where most material and fuel losses originate.
The gap
Each of these is a data-capture problem before it is a governance problem. Hardware that records automatically fixes them; policies do not.
Manual slip books allow loads to leave without a record, or with a weight lower than actual. By month-end the gap between production and sales is unexplainable.
Without beltscale data, the relationship between boulder consumed and aggregate produced is an estimate. Drift goes unnoticed for months.
Diesel issued against vehicles rarely reconciles to trip distance and load. Tyre and maintenance costs are absorbed into overheads rather than costed per vehicle.
Job-work and hired-vehicle bills get approved without a production record to check against, because the production record does not exist in usable form.
Mineral permit consumption tracked on paper rarely matches dispatch records, which creates real exposure during inspection.
Remote sites lose mobile data regularly. A cloud-only system stops billing when the connection drops, and trucks do not stop arriving.
Gross and tare read from the indicator into the transaction, with slips that cannot be edited after printing and SMS confirmation to the customer.
Continuous crusher output measured per shift and compared against boulder consumed, so conversion drift surfaces the same day.
Number-plate recognition matched against expected dispatch, and route history that flags trips deviating from the billed destination.
Diesel reconciled against distance and load, tyres tracked from fitment to disposal with cost per kilometre.
Subcontract bills validated against recorded production before approval, removing the dispute from the payment cycle.
A local server at the pit keeps weighing and dispatch running through connectivity outages, syncing centrally when the link returns.
Three things break generic ERP in a quarry. Material is measured by weight, not count. One input becomes several outputs at different values in a single process step. And the point of sale is a weighbridge at a gate, often with poor connectivity, operated by someone under time pressure with trucks queuing.
Any system that does not handle those three realities becomes a parallel record-keeping exercise, which is worse than no system at all.
Across the quarry operations we have implemented, losses cluster in the same places: unrecorded dispatch, diverted trips, diesel, and subcontractor overbilling. Each of these is a data-capture problem before it is a governance problem. Policies asking people to be careful do not fix them. Hardware that records automatically does.
The weighbridge writes the weight into the transaction. The gate camera confirms the plate. GPS confirms the route. The beltscale records what the crusher actually produced. Diesel is issued against a vehicle and reconciled against what that vehicle did. Job-work bills are checked against measured production before approval.
At that point the finance function is working from complete data, and month-end stops being an investigation.
Modules
Sector-specific modules, not a generic ERP with the labels changed.
Hole pattern, explosive issue against the magazine register and blasted volume per round, so powder factor is a number the mining engineer can argue with.
Shift-wise boulder fed against graded output from the beltscale, with conversion ratio per grade. Drift on 20mm or M-sand shows up the same day, not quarterly.
Gross, tare and net read from the indicator into the sale. Slips print once, the customer gets an SMS, and nothing can be edited after the vehicle leaves.
Issue booked against a specific tipper, excavator or genset, then reconciled with running hours, distance and load. Bowser stock reconciles at the end of every shift.
Tyre life from fitment through rotation and retreading to disposal, with cost per kilometre. Preventive service intervals by running hours and full breakdown history per machine.
Permit quantity, consumption against it and royalty payable, all drawn from weighed dispatch. Transit pass numbers sit on the invoice rather than in a separate register.
End to end
Every stage writes to the same ledger, so the number at the end reconciles with the number at the start.
Blast round recorded with explosive consumption and estimated volume, then excavator and tipper trips move boulder to the crusher stockpile. Writes to production and permit consumption.
Beltscale measures what each crusher actually produced per shift by grade. Boulder consumed is deducted, graded aggregate and M-sand are added to yard stock automatically.
Customer order or rate contract creates an authorised dispatch. At the gate the AI sensor and camera read the plate and match it before the boom barrier lifts.
Wheel loader app records the grade loaded, then gross and tare come off the weighbridge indicator. Net weight, grade, rate and vehicle land in one dispatch record.
Weighbridge slip and GST invoice print together with the transit pass reference, e-way bill is raised where the value requires it, and exit is logged against the plate.
GPS route history is compared against the billed destination, so a load sold for one site and dropped at another surfaces as an exception rather than a rumour.
Dispatches roll into customer accounts with credit limits, outstanding ageing and collection follow-up, and the same records feed royalty returns and monthly production statements.
Hardware & integrations
Automatic capture is what makes the numbers trustworthy. Manual entry is where leakage starts.
Serial or TCP link to the controller so the billed tonnage is the tonnage that crossed the platform. Removes the retyped weight, which is where short-billing starts.
Continuous measurement of crusher output by grade. Proves what the plant produced independently of what was sold, which is how conversion drift and yard shrinkage get separated.
Vehicle detection at the gate driving an automatic barrier that lifts only against an authorised dispatch. Prevents a loaded tipper leaving with no transaction behind it.
Number-plate recognition ties footage to the weighment. Stops plate swapping between the bridge and the exit, and settles disputes about which vehicle took which load.
Route history and tank-level readings per vehicle. Proves the trip actually happened and exposes siphoning that a monthly diesel total will never show.
Statutory
Filing should be a report you run, not a month-end reconstruction from paper.
Royalty on despatched quantity and district mining office transit passes per load. Both are reconciled to weighbridge records, so an inspection tests data rather than recollection.
Approved annual production limits and lease boundary conditions under state minor mineral rules. Production against sanctioned quantity is tracked as material moves, not estimated later.
State pollution control board consent under the Water and Air Acts, with conditions on capacity and dust control. Renewal dates and monitoring records held against the site.
Weighbridge verification and stamping under the Legal Metrology Act, renewed annually. An unstamped bridge makes every dispatch document on the site legally contestable.
Aggregate sales attract GST with e-invoice IRN above the turnover threshold and e-way bills on qualifying movements, generated from the dispatch rather than keyed afterwards.
Up to 95%
drop in unrecorded dispatch
1-2 weeks
single crusher go-live
5-8%
diesel cost recovered
100%
loads weighed at the gate
Recommended
industry erp
AI-powered crusher and quarry management software. Live plant monitoring, AI sensors at the gate and weighbridge capture that writes straight into the ledger.
Proof
Named engagements with the numbers that changed after go-live.
Quarrying & aggregates
A three-pit aggregate producer running manual weighbridge slip books could not reconcile production against sales. After deploying Quarry360 with direct weighbridge capture, ANPR at the gates and GPS on the fleet, unrecorded dispatch effectively stopped and diesel reconciliation identified a second, separate loss.
Answers
No generic discovery call. You will be speaking to a consultant who has implemented in this sector and can talk about your process in your vocabulary.
Send us a weighbridge slip, a BOQ or a stock register. We will configure the demo around it, so you are judging the fit — not a canned dataset.
Prefer to talk? +91 94897 49361