Wireless axle load control in the fleet of a leading FMCG market player

Problema

Integrator’s client is one of the largest distributors and retail operators in the CIS FMCG market with a 33-year long history, serving 33,000 stores in the several districts. Its logistics infrastructure includes three distribution centers and a fleet of 761 vehicles, ensuring fast and high-quality delivery while maintaining required temperature conditions.

Client encountered the problem of lacking axle load control systems when transitioning from European to Chinese trucks. Unlike European models, which come equipped with axle load monitoring systems, Chinese vehicles do not provide accurate data on current axle loads. This created a risk of overloading and consequent fines. Moreover, incorrect load distribution leads to accelerated equipment wear. The company was actively looking for a way to monitor and prevent overloading.

Solución

To address this issue, the eCargosens axle load monitoring system by Escort was chosen. The customer needed to equip their trucks with reliable and accurate devices, so the company’s specialists focused on the following criteria when selecting the solution:

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Learn more about eCargosens

Sensor polling frequency. Fast data updates during loading allow for even distribution of cargo across the axles.
Battery life without replacement. With a self-discharge rate of no more than 1% per year, the device ensures long-term operation.
Performance in sub-zero temperatures. The power source is designed for a wide temperature range, enabling reliable operation in any weather conditions.

All of these requirements are met by Escort sensors. Another key reason for choosing Escort for the axle load monitoring solution was the company’s positive experience with other devices from the same manufacturer already successfully used on their trucks:

TH-BLE temperature and humidity sensors – for monitoring food transportation conditions in refrigerated trucks
Fuel level sensors – for tracking fuel consumption and monitoring truck operations

The eCargosens system includes wireless sensors installed in the vehicle’s air suspension circuits and an in-cab control unit.

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Load data is transmitted via Bluetooth 5.0 Long Range to the monitoring system (in the clients’ project, to Galileosky trackers), as well as to the driver’s mobile app and the I-5 digital display installed in the truck cabin.

Advantages of the eCargosens axle load monitoring system:

Wireless design

Greatly simplifies both system integration and long-term use – no complex cabling required

User-friendly control

Convenient mobile app displays axle load data on any mobile device for easy monitoring

Wide operating temperature range

Performs reliably from -45°C to +50°C, suitable for any climate

Sensor polling frequency

Enables even distribution of cargo across axles, helping to prevent overloads

Extended battery life

Long-lasting power supply without replacement ensures years of uninterrupted operation

Resultados

The eCargosens system enabled the client to take a more efficient approach to fleet loading by:

Avoiding dispatch of overloaded vehicles

Properly distributing cargo across axles thanks to real-time load data

Completing direct routes without detours to bypass weight control checkpoints

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Plans

Currently, over 40 trucks are equipped with the eCargosens system. In 2025, the company plans to install it on an additional 20 vehicles. Moreover, the client intends to equip all newly acquired trucks – at least 50 units – with the system. This will enable full axle load control across the entire fleet and significantly reduce the risk of overloading.

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