Lorem Ispum

Detect process fluctuations in nonwoven production at an early stage

Continuous inline measurement data for stable material properties and reproducible quality.

Home Measurement Technology Industries Nonwoven Industry

When material distribution and moisture content vary, processes fall out of sync

In nonwoven production, thermal, mechanical and material‑dependent influences act on the product simultaneously. Fluctuations in fibre deposition, binder content or drying lead to changes in thickness, basis weight and strength. Without continuous monitoring, local inhomogeneities develop, spread along the line and only become visible later in the process. If these deviations are detected too late, they can only be corrected to a limited extent – often with direct impacts on waste, energy consumption and process stability.

Nonwoven materials often exhibit rapid, locally confined changes in material distribution or moisture. Inline measurement systems make it possible to visualise these developments at the moment they arise and use them for process control – long before they produce measurable effects in the product.GreCon Engineering

Lack of transparency in the process – reliable facts from the industry

In many production lines, quality‑relevant parameters are recorded only selectively, with delays, or in the laboratory. Continuous measurement values that can flow directly into process control are missing. As a result, deviations are often detected only when they have already manifested themselves in the finished product – too late for effective corrective intervention.

25 %

Material usage – typical overdosing without inline measurement

> 70 %

most quality deviations occur before final inspection

> 72 h

Time delay between process deviation and laboratory result

Solutions and concepts

A stable nonwoven production process requires measurement values generated exactly where the process takes place. Inline systems detect local deviations immediately and make them available for process control. They not only provide quality indicators, but also form the basis for active regulation, reproducible material properties and efficient use of resources.

On this basis, the following GreCon systems support the key measurement tasks in nonwoven production.

Inline thickness measurement

GreCon THICKNESSCONTROL continuously and fully integrates thickness measurement into the nonwoven production process. The measurement is carried out either non‑contact or contact‑based – depending on the material and process requirements. The measured values reveal local thickness variations, support thermal process control and reduce production‑related fluctuations.

LEARN MORE

Inline moisture measurement

GreCon MOISTURECONTROL continuously measures moisture content using infrared or microwave‑based sensors. The inline values provided enable precise drying control, energy savings and the reduction of moisture‑related material fluctuations.

LEARN MORE

Inline Weight per unit area measurement

MATCONTROL monitors basis weight almost across the full material width and detects local inhomogeneities at an early stage. The high‑resolution X‑ray technology delivers millions of measurement points per minute and reveals density changes, variations in fibre deposition or material‑related streak formation.

LEARN MORE

For­eign ob­ject de­tec­tion

The high‑resolution X‑ray detection system identifies foreign bodies such as metal or mineral inclusions already during material formation. This makes it possible to locate sources of errors at an early stage and prevent damage in subsequent process steps.

LEARN MORE

The future of industrial measurement technology

“Rising line speeds, increasing cost pressures and ever‑tighter tolerances are making continuous inline measurement a central component of modern nonwoven production. Inline measurement systems no longer provide only quality indicators – they enable data‑driven process control and reduce reactive interventions in favour of active, stabilising control strategies.”GreCon Engineering
Workers display holographic data in factory hall

Consequences of missing or insufficient measurement – more than just scrap

Production deviations often develop gradually. Without continuous measurement data, local material distribution issues, moisture fluctuations or foreign bodies remain undetected for a long time – until scrap, complaints or downtime occur.

Economic consequences
Increased material consumption, unplanned downtime, rising unit costs.

Operational consequences
Unstable processes, frequent readjustments, overload of quality control.

Strategic consequences
Production performance becomes harder to predict, reduced competitiveness.

The cost of doing nothing is high. Reliable measurement technology is not a convenience option – it is a strategic prerequisite for stable processes.

finger in front of laptop points to holographic statistics

Challenges in the nonwoven industry

The production of nonwoven materials is characterised by high line speeds, complex material combinations and sensitive process windows.

Typical challenges

  • inhomogeneous material distribution due to uneven fibre deposition
  • fluctuating moisture levels caused by variable drying conditions
  • limited access to measurement points in thermal and mechanical process zones
  • rapid process reactions that require continuous measurement
  • delayed laboratory analyses as the only basis for decision‑making

The result? Processes with high variation and error potential.

These risks are not theoretical – they occur daily, often go unnoticed and lead to significant costs.
That is why industrial measurement technology is not optional, but essential.
And this is exactly where Fagus‑GreCon comes into play.

GreCon Product overview

Everything at a glance: our measurement technology solutions

The measurement values obtained with GreCon systems provide precisely the data needed to operate nonwoven plants efficiently, reproducibly and reliably – inline, continuously and exactly where process deviations occur.

Supported measurement and optimisation tasks

  • Thickness measurement
  • Moisture measurement
  • Weight per unit area measurement
  • Foreign‑body detection
  • Density measurement
  • Forming optimisation
  • Emission determination

The systems can be combined modularly, integrated into existing plants and adapted to new line concepts. At the centre is a robust, process‑integrated measurement approach that forms the foundation for stable processes and reliable decision‑making.

We look forward to hearing from you.

Please fill in all mandatory fields marked with an asterisk (*).

Fields marked with * are required.

I hereby consent to the processing of my personal data in accordance with the data policy.