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Optimisation of material distribution in wood-based mats: less scattering, more control

GreCon FORMATOR

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The GreCon FORMATOR combines precise X-ray measurement with intelligent control. This turns variation into structure: the material distribution is continuously measured and automatically adjusted – for stronger edges, measurably better boards and less waste.

Your added value with GreCon FORMATOR

  • Measurably reduce waste
  • Targeted edge stabilisation
  • Targeted material savings
  • Automatic compensation for dispersion
  • Improved quality indicators in the process
  • Traceable, transparent process data
  • Lower raw density with the same product quality
  • Stability during product changes
  • Lower energy consumption
  • Fewer manual interventions

FORMATOR – Measurement and control in interaction

Material distribution determines product quality, resource utilisation and process costs. However, conventional systems usually regulate based on intuition – or too late. The FORMATOR shows where there is too much or too little material – and intervenes directly.

It works in conjunction with a segmented scalper to remove material from the moulding line and then measures whether the segment of the scalper needs to be raised or lowered. This opens up new optimisation potential for the production of high-quality wood-based panels. In addition to significantly reducing scatter variations, the FORMATOR can also be used to produce special mat profiles.

GreCon FORMATOR in detail

The FORMATOR consists of two components:

GreCon MATCONTROL HF scans the mat with high-resolution X-ray technology and detects exactly where there is too much or too little material. GreCon Segmented SCALPER reacts automatically – each segment can remove or leave material as required. This stabilises the cross-distribution of the mat – for reproducible quality and lower raw material consumption.

The GreCon FORMATOR automatically standardises the material distribution in the wood-based material mat, resulting in remarkable improvements in board quality and significant savings in material, process and logistics costs.

The combination of a segmented scalper and MATCONTROL HF X-ray scanner achieves a high degree of spreading accuracy. Both systems are integrated into a control loop, enabling the material distribution on the mat to be adjusted automatically for the first time. The MATCONTROL HF determines the weight per unit area of the mat with high resolution and precisely controls the position of the combing rollers of the segmented scalper. In this way, for example, spreading fluctuations are significantly reduced in order to produce a more homogeneous board.

  • Individually adjustable segmented combing rollers
  • Modern control centre
  • Robust walkway for easy maintenance
  • Software module for automatic control of the combing rollers
  • Customised network connection

Whether MDF, OSB or chipboard – the FORMATOR ensures more uniform mats everywhere. It delivers measurable advantages, especially with changing recipes or product dimensions:

  • Shorter start-up times
  • Higher line stability
  • Fewer manual readjustments
  • Firm edges and lower sanding allowances
Gre­Con FOR­MATOR, consisting of MATCONTROL HF mat scanner and segmented scalper installed in the production line
Gre­Con FOR­MATOR mat scanner MATCONTROL HF with segmented scalper for optimising material distribution in wood-based mats

Raw material savings with consistent product quality

The precise basis weight measurement of the MATCONTROL HF not only significantly reduces safety margins, but also lowers the target value.

Material savings are achieved while maintaining consistent product quality. The significant reduction in scatter fluctuations means that downstream production equipment is subjected to less stress. The service life of processing tools such as sanding belts, saw blades or milling heads is increased. The board surface becomes more uniform and is therefore easier to coat. Paint consumption is reduced.

The improved product quality has a positive effect on complaint rates. The combination of homogeneous material distribution and reduction of the target value enables higher production speeds and output quantities.

With a 2% reduction in raw material consumption and an annual production of 300,000 m³, practical values indicate savings of over £787,000 per year – simply through better distribution while maintaining the same quality. What's more, up to 5,000 tonnes of CO₂ are saved each year thanks to reduced material and energy consumption.

Before:

  • Non-uniform mats
  • Unstable edges
  • Higher scrap rate
  • Time-consuming readjustment

After:

  • Even cross-distribution
  • Stable edges
  • Lower material consumption
  • Reproducible product quality

  • Analysis of your line geometry and product requirements
  • Adaptation of FORMATOR components (number of segments, connection, interface)
  • Training, installation and commissioning
  • Complete visualisation and control integration

We look forward to hearing from you.

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