WeighUp: Smarter Alcohol Inventory

For bars and restaurants, missing alcohol is a costly problem—20% of alcohol inventory goes unaccounted for due to free drinks and overpours, significantly cutting into profits. If overpouring could be tracked and corrected, businesses could recover lost revenue.

WeighUp had developed software to address this issue but needed a smart scale to integrate with their system. The challenge was designing a solution that could track which employee was pouring, when each drink was poured, and precisely how much alcohol was used. The scale needed to provide real-time insights into inventory levels, connect seamlessly to the existing POS system, and generate dashboards with employee pouring data and reorder recommendations.

The design also needed to balance oversight with employee trust—providing accountability without making staff feel like they were under constant surveillance.

Ovyl handled every aspect of the product, including PCB design, firmware, mechanical engineering, and industrial design. Given the number of devices required, a wireless solution was impractical. Instead, we developed a daisy-chained wired connection that eliminated the need for battery replacements and avoided interference from hundreds of Bluetooth signals.

Iterating toward the most accurate and reliable solution

To ensure accurate weight tracking, we iterated through dozens of prototypes, ultimately selecting a microcontroller that read a single bar-type load cell. This allowed us to keep the scale compact enough to blend seamlessly with bar decor. However, accuracy posed unique challenges. Bartenders place bottles down inconsistently, and alcohol volume fluctuates with temperature. To compensate, we created algorithms that detect and adjust for level drift due to placement and temperature changes over time.

A recessed bottom design with multiple cable slots allowed for adjustable cable length and exit angles, accommodating different bar layouts. We selected 3.5mm jacks—traditionally used for audio—as affordable, waterproof connectors that rotate freely, giving installers maximum flexibility in configuring the system.

Ensuring effectiveness before full-scale rollout.

Following a proof of concept with 100 connected devices, the system underwent a real-world pilot test in a restaurant setting. After demonstrating its effectiveness in tracking and reducing alcohol loss, the client moved forward with full-scale manufacturing.This is an optional subhead

The Weigh Up scale precisely measures the weight of liquor bottles between pours, comparing usage data against sales and employee schedules to track and prevent inventory loss.

By providing real-time inventory tracking and actionable insights, Weigh Up empowers bars and restaurants to reduce waste, optimize reordering, and protect their bottom line.