Fagus-GreCon introduces radar technology to industrial quality control

With GreCon FOAMCONTROL, the measurement technology specialist based in Alfeld is adding radar technology to its portfolio for the first time – with several systems already in industrial operation.

Many of the materials used in mattresses, furniture, vehicles, packaging and insulation start out as foam produced on an industrial production line. Key quality parameters include the material’s thickness, weight per unit area and actual density.

To assess these parameters during production, GreCon FOAMCONTROL uses a new measurement technology designed for continuous process monitoring in foam manufacturing. Initial installations at well-known companies in the Hanover region have already demonstrated its practical value. The systems are operating in live production environments, showing that radar technology can be reliably integrated into industrial processes.

Radar waves reveal what lies beneath the surface

What sets GreCon FOAMCONTROL apart is how it measures as well as what it measures. Radar waves penetrate foam and plastic materials without making contact. The system continuously measures thickness and weight per unit area, using these values to calculate density. It can also reveal variations and inconsistencies within the material – information that cannot be obtained through surface inspection alone.

FOAMCONTROL operates without ionising radiation, so statutory radiation protection measures and complex shielding are not required. Compared with X-ray-based methods, its radar sensors also enable faster measurements.

The system has also been developed with the conditions found in industrial production environments in mind. Changes in temperature, dust and deposits can affect measurement systems. A reference unit therefore continuously monitors ambient conditions and takes them into account during measurement.

FOAMCONTROL marks the first use of radar technology in Fagus-GreCon’s measurement technology portfolio. The first systems are already operating successfully in industrial environments.

Measuring quality as it takes shape

The key difference is when the information becomes available. Conventional spot checks provide only isolated snapshots of an ongoing production process. Material quality can change between checks: thickness may fluctuate, density may vary or irregularities may develop within the material. If these deviations are not detected until the next inspection, a substantial volume of production may already be affected – costing material, time and money.

By contrast, FOAMCONTROL continuously supplies measurement data from the production process. Changes become visible while there is still an opportunity to respond immediately.

This gives manufacturers a reliable data basis for using materials more precisely, reducing safety margins and maintaining consistent, reproducible product quality. It also reduces the need for manual inspections.

“We did not want to develop another variation of an existing measurement principle. Our aim was to create a technology that makes relevant material parameters continuously available during production while remaining straightforward to integrate into industrial processes. Radar gives us exactly the capabilities we were looking for. The fact that several systems are already in industrial operation confirms both our technological approach and market demand,” says Christian Angel, Product Manager at Fagus-GreCon.

Designed for different production lines

FOAMCONTROL is suitable for foam and plastic materials produced in continuous webs or sheets, including extruded foams, chemically produced foams and block foam. Depending on the application, the sensors can be configured for multiple fixed measurement tracks or as a traversing system.

The system can be integrated into both new and existing production lines, enabling continuous quality assessment directly within the production process.
 

Further information about [GreCon FOAMCONTROL]