Steel · Coal · Cement · Aggregate · Logistics · Weighbridge India

AI Weighbridge Fraud Detection
Software India

Your weighbridge processes ₹50 crore of material every month. How many of those transactions are fraudulent? XPndAI's AI monitors every weighing in real-time — weight tampering, vehicle substitution, overloading, data manipulation — and alerts before material leaves your gate. From ₹8 lakh.

📋 Free Demo 💬 WhatsApp
Real-time fraud alertsWorks with existing hardwareCCTV integrationERP integrationFrom ₹8 lakhFull source code
₹8L+
Single site setup
3–5%
Avg fraud rate at unmonitored sites
2 mo
Typical ROI break-even
100%
Transactions monitored
6–8wk
Setup to go-live

What the AI Detects

Every fraud vector that costs India's heavy industry ₹500–5,000 crore/year — caught in real time.

⚖️
Physical Fraud

Weight Manipulation

  • Partial loading — material short of invoice weight
  • Dead weight addition on outgoing trucks
  • Load cell tampering patterns (gradual drift detection)
  • Multiple weighings of same consignment
  • Tare weight inflation
🚛
Vehicle Fraud

Vehicle & Driver Fraud

  • Vehicle substitution (different truck, same ID)
  • CCTV plate vs RFID mismatch
  • Overloading beyond permitted limits
  • Unauthorized vehicle entry
  • Repeat visit in too-short interval (jockeying)
💻
Data Fraud

Digital/Software Fraud

  • Manual weight override by operator
  • Database record editing post-transaction
  • Timestamp alteration
  • Supervisor bypass without approval trail
  • API data injection
🤝
Collusive Fraud

Pattern & Collusion Detection

  • Same operator approving same driver repeatedly
  • Unusual transaction timing (midnight, weekends)
  • Statistically improbable weight consistency
  • Supplier-specific fraud clusters
  • Seasonal anomaly detection
📦
Material Fraud

Grade Substitution

  • Weight-density profiling for material grade
  • Expected weight range by material type and truck size
  • Variance from historical supplier profile
  • Cross-check with lab test records
📊
Audit AI

Audit Trail & Evidence

  • Photo evidence per transaction (CCTV frame capture)
  • Confidence score for each alert
  • Exportable evidence package for legal action
  • Inspector dashboard with trend reports
  • GST reconciliation cross-check

Industries Served

🏭

Steel Plants

Scrap inward, coal inward, finished goods outward

⛏️

Coal Depots

Coal intake, dispatch, quality-weight cross-check

🧱

Cement Plants

Limestone inward, clinker, finished cement outward

🪨

Aggregates/Quarries

Stone, gravel, sand — dispatch fraud prevention

🌾

Grain/Agri Mandis

Procurement weight fraud, mandi procurement AI

🚢

Port & Logistics

Container weight, bulk cargo, freight reconciliation

Pricing

Single Location

1–3 Weighbridges

₹8–12 Lakh one-time+ ₹50K–1L/year maintenance
  • Real-time fraud detection AI
  • Existing hardware integration
  • CCTV integration (up to 4 cameras)
  • Alerts dashboard
  • 6–8 week setup · Full source code
Most Popular

Multi-Location 5–10 Weighbridges

₹15–20 Lakh one-time+ ₹1–2L/year maintenance
  • Centralized monitoring dashboard
  • Cross-location pattern detection
  • ERP integration (SAP/Oracle/custom)
  • Advanced audit reporting
  • Full source code
Enterprise

Plant-Wide + ERP Integration

₹20–25L+ one-time+ ₹2–3L/year maintenance
  • SAP/Oracle MM integration
  • GST reconciliation AI
  • Legal evidence package generation
  • On-site training + SLA
  • Full source code

FAQ

How does AI weighbridge fraud detection work? +

The AI integrates with your existing weighbridge hardware and monitors every transaction in real-time. It baseline-models normal weight distributions for each vehicle type, material, supplier, and time window. Anomalies — a truck that typically delivers 22 tonnes weighing 18, a vehicle ID not matching the photographed plate, statistically improbable weight consistency — are flagged instantly with confidence scores and photo evidence.

What types of fraud does it detect? +

Physical tampering, vehicle substitution, operator data override, collusive fraud patterns, material grade substitution, timestamp manipulation, and unusual transaction timing. Basically every fraud vector a determined operator or driver can attempt.

Does it work with our existing weighbridge hardware? +

Yes — we integrate with Avery Weigh-Tronix, Mettler Toledo, Fairbanks, Essae, and custom builds via API, serial port, or database polling. No hardware replacement. CCTV integration uses your existing IP cameras.

What is the ROI? +

Typical steel plant with 500 truck movements/day: if 3% are fraudulent at ₹2,000 loss each — ₹30,000/day = ₹90L/year. AI system: ₹8–15L setup. Break-even under 2 months.

What is the pricing? +

₹8–12L single site, ₹15–20L multi-location, ₹20–25L+ enterprise with ERP. Full source code included. No per-transaction fees.

Stop Losing Crores to Weighbridge Fraud

Free discovery call — we'll estimate the fraud loss at your site before you spend a rupee.

📋 Free Demo 💬 WhatsApp
📋 Free Demo 💬 WhatsApp