20 Nov 2025

WHY YOUR CALIBRATION SCHEDULE IS FAILING - AND HOW TEST WEIGHTS HELP YOU UNDERSTANDING THE REAL ISSUE

Many organisations follow regular calibration schedules and assume this alone ensures accurate measurements. However, accuracy problems can still appear even when devices are calibrated on time. This can be frustrating, especially when it is not immediately clear what caused the inconsistency.

Test weights provide valuable information in these situations. They act as indicators of how well the surrounding processes - storage, handling, environment, and operator technique -  are working. When something is not right, test weights often reveal the issue earlier than the calibration schedule does.

This article explains the common gaps that can weaken a calibration plan and shows how test weights can help you understand and correct those issues with confidence.

COMMON CALIBRATION GAPS THAT OFTEN UNNOTICED

Even well-managed systems can experience three common oversights that affect accuracy.

STORAGE CONDITIONS THAT AFFECT WEIGHT STABILITY

Test weights are sensitive to their environment. Factors such as temperature changes, humidity, airborne dust, and contact with magnetic fields can influence how a weight performs. When weights are stored on open benches or handled without the right protective measures, small changes occur gradually. These changes may not be obvious, but they can lead to inconsistent results that appear unpredictable. 

USING WEIGHTS THAT ARE OUT OF TOLERANCE BETWEEN CALIBRATIONS

Weights naturally drift over time. If they are only checked once a year, a weight may fall out of tolerance months before its next recertification. Daily accuracy checks using that weight can then produce misleading results. This does not mean the scale is faulty – it simply means the reference point is unreliable.

ASSUMING CALIBRATION RESULTS REFLECT REAL-WORLD USAGE

A device may perform well in a controlled calibration environment yet behave differently in its actual workspace. Airflow, vibration, temperature differences, and even surface stability can influence performance. Without checking the device both before and after calibration, it is easy to miss changes caused by the surrounding environment.

HOW TEST WEIGHTS HELP IDENTIFY PROCESS ISSUES

Test weights do more than confirm whether a device is accurate. They highlight which part of the workflow may be causing problems.

By observing how a scale responds to an unknown weight, you can detect:

• Operator handling differences
• Variations in cleaning routine
• Environmental shifts
• Inconsistencies in storage or maintenance
• Weight drift
• Subtle performance changes during daily use

For example, if accuracy checks fail at certain times of the day, this may point to temperature cycles or airflow changes. If results vary depending on who performs the checks, technique may be the underlying factor. These observations guide you toward solutions that strengthen the entire process.

If you don't already have robust calibration equipment in place, you might consider exploring our range of quality test weights and stillages.

THE SIGNIFICANCE OF PROCESS DRIFT

Process drift refers to small changes in routines or conditions that gradually affect accuracy. Although these changes may seem minor, they can lead to larger issues over time. Some common consequences include:

• Ingredient or material waste due to incorrect measurements
• Unnecessary calibration call-outs caused by misinterpreting routine failures
• Audit findings related to documentation or traceability gaps
• Extending troubleshooting periods, as teams search for errors that are not equipment-related

Understanding the source of drift helps prevent these situations and supports more reliable performance.

USING TEST WEIGHTS TO IMPROVE WORKFLOW INTEGRITY

You can use test weights, like those found here, as part of a structured approach to maintenance consistency and identify issues early. The following steps can help create a stronger, more reliable workflow.

VERIFY PERFORMANCE REGULARLY

Brief daily or pre-use checks with test weights help build a clear picture of how a device performs over time.

CHECK ENVIRONMENTAL CONDITIONS WHEN RESULTS CHANGE

If a reading appears unusual, consider external influences such as airflow, vibration, or movement of the equipment.

ASSESS WEIGHT STABILITY EACH MONTH

A simple monthly check can confirm that weights remain within tolerance between calibrations.

OBSERVE OPERATOR TECHNIQUE

Consistent handling - such as using gloves, cleaning surfaces, and avoiding unnecessary contact - helps maintain accuracy.

TRACK WEIGHT & DEVICE PERFORMANCE OVER TIME

Recording even small deviations allows you to identify patterns. These patterns often point directly to underlying causes.

MAINTAIN CLEAR DOCUMENTATION

Good records help support audits, investigations, and continuous improvement efforts. They also make future troubleshooting more efficient and confident.

WHY TEST WEIGHTS ARE AN EFFECTIVE EARLY-WARNING TOOL

Because test weights provide a stable reference point, they offer insight into changes occurring within your process. They help identify whether an issue lies with the device, the environment, or the procedure itself.

In this way, test weights support:

• Early detection of drift
• Stronger compliance
• Better operator consistency
• Fewer unexpected failures
• More predictable calibration outcomes

Using test weights regularly builds a clearer, more reliable understanding of your system’s performance.

CONCLUSION

A calibration schedule is an important part of any quality system, but it is only one piece of the overall process. Test weights help reveal how well the supporting practices - handling, storage, environment, and documentation - are functioning.

By using test weights as an ongoing educational tool rather than a simple pass/fail device, organisations gain a clearer view of their workflows. This leads to improved accuracy, stronger compliance, and a greater sense of control over measurement performance.