EcoRodovias implements Kistler WIM for MLFF tolling and weight enforcement in Brazil

Winterthur, December 2025 – KiTraffic Digital, the world’s most accurate Weigh In Motion (WIM) system, is ushering in a new era of electronic tolling on Brazilian highways: multi-lane, free-flow traffic monitoring with reliable axle counting – and no need for static stations. Also in place since 2024: direct weight enforcement with KiTraffic Basic – following the first-ever successful approval by Brazilian authorities for dynamic truck weighing on highways.

With over two million kilometers of roads, Brazil has the fourth-largest road network globally. Managing infrastructure and ensuring traffic safety present major challenges here, as they do throughout the world. Brazil’s response was to adopt a new strategy in 2023: automated traffic monitoring with maximum functional integration. Multiple gantries across the highway network now support electronic tolling and dynamic truck weighing without disrupting traffic flow.

EcoRodovias, one of the largest highway concessionaires in Brazil, manages approximately 4,800 km of roads across eight of the country’s states. The company has been using the KiTraffic Basic Weigh In Motion system from Kistler, which was legalized for direct weight enforcement by INMETRO, Brazil’s national metrology institute, in August 2024. The homologation (type approval) for class A1 means that the WIM system can measure gross vehicle weight (with accuracy of ±2.5%) and axle loads (±4%) of trucks at highway speeds of up to 90 km/h – so, for the first time in Brazil’s history, direct enforcement by federal agencies is now allowed. The first installation of the so-called HS-WIM (High-Speed Weigh In Motion) project in Uberlândia operates with a layout of eight Lineas sensors per lane. To date, direct enforcement with KiTraffic Basic on six lanes has led to 17,676 fines for overloaded trucks. By way of comparison, conventional weighing on 38 lanes resulted in 41,420 fines, so the output from Weigh In Motion is significantly higher – and no evasions are possible.

Electronic tolling on multiple lanes without toll stations

As the next step, EcoRodovias is introducing Kistler’s KiTraffic Digital WIM system to enable multi-lane free-flow tolling (MLFF). In this concept, distributed gantries monitor highways automatically, so users pay their tolls according to the sections they have actually used. MLFF systems have

faced two main challenges: lane changes to evade tolling, and inaccurate axle counting based on optical recognition alone. KiTraffic Digital overcomes these challenges thanks to its revolutionary technology, which features over 60 sensing elements embedded in every single sensor. So, even if a driver tries to evade electronic tolling by changing lanes or driving between lanes, the system ensures correct axle counting and tolling. The latest Weigh In Motion technology from Kistler has significantly reduced the percentage of invalid data, from over 30 to less than 5 percent.

New Weigh In Motion: multiple functions in one system

Leandro Montanher, Head of Sales at Kistler Brazil, comments: “What’s more, MLFF with KiTraffic Digital can be combined with weight enforcement and – possibly in the future – even with additional applications. All functions are carried out fully automatically in free-flow traffic, with no need for tolling stations, static scales, or any other disruptions to traffic”. The solution promotes a smooth and uninterrupted flow that is monitored and safe. This new approach to Weigh In Motion for traffic management on highways not only protects roads and reduces tolling effort, but also helps to lower emissions and improve resource efficiency.

EcoRodovias had previously installed four KiTraffic Digital systems in 2024 – two each in Jaboticabal and Itápolis in São Paulo state, with a total of eight lanes. Four more sites have already been installed in 2025, including sites in Dobrada and Taiúva, and at least six additional MLFF stations are due for installation in 2026. Final words from João Paulo Capelatto, Automation Manager at EcoRodovias: “We’ve launched the first MLFF toll system in São Paulo at our Ecovias Noroeste Paulista site. This new electronic tolling system is a major step toward modernizing, sustaining, and equipping our highways – providing a seamless, smoother, and safer experience for drivers.”