Falco WAC

Real-world validation: Already calibrated 1,500+ machines, conducted 9,000+ test sessions, and captured over 7,46,542 readings. Every pouch, every reading — tracked with precision.

In high-speed packaging operations, especially in sectors like dairy, flour, agrochemicals, and pharmaceuticals, weighment isn’t just a formality — it’s a frontline quality gate.

Yet, in most factories today, weighment checks are still manual. Operators take periodic samples, record readings on paper sheets, and hope the next shift continues the discipline. It’s a system built on habit, not reliability.

What actually happens?

• Pouch weights get missed
• Defects aren’t recorded
• Root causes remain undocumented
• Compliance becomes a post-event scramble

That’s where Falco WAC (Weighment Calibration) fixes all of this — with a simple but powerful BLE-connected system that logs every check digitally and makes data actionable in real time.

The Real Problem in Weighment Logging

Let’s break it down:

• Sampling inconsistency: Operators may forget or delay weighment checks, especially in multi-line setups
• Data loss: Handwritten logs fade, tear, or disappear entirely
• Zero traceability: When complaints arise, there’s no record to trace back defects or patterns
• Compliance burden: Audits become manual firefighting, gathering physical logs from different machines
• Risks due to Underweight filling of pouches
• Losses due to excess wight filling per pouch

These are not just inefficiencies — they are risks. They impact brand trust, regulatory compliance, and customer satisfaction

What Falco WAC Does Differently

Falco SWAS — Service, Warranty, AMC, Spares — is more than just another module. Falco WAC creates a closed-loop, digital-first weighment process:

• Bluetooth Integration
  • Connects directly to your existing weighing scale using BLE (Bluetooth Low Energy). The operator never has to punch weight readings manually — the system fetches it live
• Auto-Sample Prompts
  • Set sampling frequency per line or shift. Falco triggers timely alerts when it’s time to check a pouch — no one “forgets” anymore
• Real-Time Logging
  • As soon as a sample is weighed, the pouch weight, defect type (if any), and even operator comments are logged — all synced to the cloud
• Instant Alerts
  • o If a deviation is logged or a sample is missed, supervisors are instantly notified. There’s no lag between problem detection and response
• Multi-Line Ready
  • Works across multiple lines and packaging formats. Configure rules per SKU, per machine — with full traceability across batches

Control Losses, Avoid Compliance Risks

With manual weighment:

• You're losing money on every overweight pouch — often without even realizing it. A few grams extra across thousands of pouches = massive product loss
• You're risking non-compliance with every underweight pack — leading to potential penalties, market returns, and damaged brand trust
• You're missing calibration errors until it’s too late — and there’s no reliable trail to prove when a scale was last checked or if a reading was accurate

Falco WAC eliminates all three risks

• Accurate digital logs for every check
• Auto-alerts for missed samples or out-of-spec results
• A machine calibration audit trail that’s always ready for inspection

This is not just a QC tool — it’s a profit protection system

What This Means on the Factory Floor

You no longer rely on training and memory. The process itself becomes intelligent:

• Operator-friendly: No extra steps. Just weigh, record, move on
• Supervisor visibility: Know who did what, when — with no ambiguity
• Zero ambiguity: No more second-guessing whether a check was done or not
• Better response: Quickly identify trends like underfill, seal issues, or scale calibration drifts — before it’s too late

This isn’t about punishing operators. It’s about empowering them with a system that supports their routine and protects the product.

Already Deployed Across 1500+ Machines

Falco WAC isn’t a lab prototype — it’s proven in the field. From dairy cooperatives to large FMCG packers, WAC has been integrated across real-world environments. It has replaced outdated weighment sheets with a modern, transparent process that everyone from QA to audit teams can trust.