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Detect fluctuations in film extrusion at an early stage

Continuous inline measurement values for stable film thickness and reproducible material distribution.

Home Measurement Technology Industries Plastics Processing Industry

When thermal or mechanical deviations occur, they alter the film thickness

Plastic films react sensitively to fluctuations in melt temperature, throughput, viscosity or haul‑off speed. These influences have an immediate impact on thickness, layer distribution and material homogeneity. If deviations only become visible at the end of the roll, they have already manifested throughout the entire production process and can only be corrected to a limited extent.

Extrusion and calendering processes react strongly to the smallest process fluctuations. Inline measurement systems make these changes visible as they occur – not only once they appear in the finished product.GreCon Engineering

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

In many extrusion and calendering processes, quality‑relevant parameters are still recorded with delays or only selectively. Without continuous inline measurement, the transparency needed for stable, efficient and reproducible processes is missing. The consequences are well documented.

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 precise plastic film production process requires measurement values that are generated continuously and inline exactly where deviations occur. These data form the basis for stable film thickness, uniform material distribution and reproducible quality – regardless of process speed or material variations.

inline thickness measurement

GreCon THICKNESSCONTROL continuously measures the film thickness along the web and visualises local variations in real time. The measurement data support the control of extrusion, calendering, haul‑off and cooling, enabling more stable process operation.

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Material distribution analysis

GreCon MATCONTROL HF monitors weight per unit area and material distribution across almost the full material width. The system identifies layer‑build fluctuations, local densifications and inhomogeneities early in the process and provides reliable data for active process control.

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Foreign‑body detection

MATCONTROL HF detects foreign bodies such as metallic or mineral particles during production. Affected areas can be selectively removed or reworked.

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The future of industrial measurement technology

“Rising line speeds, more complex layer structures and tighter tolerances increase the demand for reliable real‑time data. Inline measurement technology is becoming a central component of process control because it visualises deviations at the moment they arise.”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, variations in material distribution, changes in thickness or internal irregularities remain undetected – until scrap, complaints or shutdowns 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 plastic film industry

The measurement values obtained with GreCon measurement systems provide exactly the data and information required to operate plastic film production lines efficiently, reproducibly and reliably. Measurement is performed inline, continuously and process‑integrated – exactly where deviations occur and can still be influenced.

Typical challenges

  • Thickness measurement (THICKNESSCONTROL)
  • Weight per unit area & material distribution (MATCONTROL HF)
  • Foreign‑body detection (MATCONTROL HF)
  • Monitoring of foamed or thick plastic webs (FOAMCONTROL)

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
  • Weight per unit area & material distribution
  • Foreign object detection
  • Monitoring of foamed or thick plastic films 

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.

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