Weighing system issues in fixed weighing hopper

our weighing system has the following material flow sequence:

Storage Hopper → Vibrofeeder → Fixed Weighing Hopper → Vibrofeeder → Conveyor Belt → Discharge Pipes → Furnace

Whenever we perform a drop test, and measure the actual discharge it always comes almost accurate

However, during actual production, when material is discharged into the furnace bin:

  • The chemical analysis shows higher alloy addition than what the weighing hopper indicates.
  • The chemistry suggests that ~20 kg more material must have been added than the weighing hopper measured.
  • This level of chemical change is not theoretically possible with the weight recorded by the weighing hopper.
  • So now the productions guys are behind us that the weighing hopper is under‑reporting the actual discharged quantity during real operation.

We have checked the load cells, cable shielding , healthiness of the weighing system, load cell mounting vibrofeerders also not touching the weighing hopper.

What could be the reason for this issue. I am puzzled.
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