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Manufacture of glass wool and rock wool

Inline measuring systems from Fagus-GreCon. For high product quality and stable processes in insulation production.

In mineral wool production, faulty batches can occur suddenly, triggered by an accumulation of molten glass or stone (hot spots) or of binder (wet spots). Fluctuations in the process, on the other hand, do not become apparent straight away and often go unnoticed for a long time. Fagus-GreCon supplies the measurement systems that detect both directly on the line. This helps to minimise waste and unplanned downtime.

Mineral wool production: At the end of the line, it is already too late

Varying air flows, dynamic fibre formation and thermal fluctuations shape the production of glass and stone wool. This results in deviations in material distribution and moisture; usually gradual, rarely immediately apparent. Along the line, these effects add up and affect energy consumption, homogeneity and consistent quality alike.

Mineral wool production in particular shows: if you only measure at the end of the line, you react too late. Inline measurement technology from Fagus-GreCon continuously monitors the critical parameters and makes fluctuations visible before they become a problem.

Insulation mats are complex, inhomogeneous structures. Only continuous inline measurement reveals how fibres are distributed and where process‑critical deviations occur.GreCon Engineering

The reality in mineral wool production: Less control, higher costs

In many insulation plants, key parameters such as material distribution, basis weight and moisture are not continuously monitored. Random checks or delayed laboratory analyses do provide values, but no continuous basis for the process. The consequences: higher material usage, unnecessary energy losses and fluctuating product quality.

Our solutions for mineral wool production: Modular and in use worldwide

For more than 50 years, Fagus-GreCon has been developing measuring systems for industrial manufacturing processes; in use worldwide and tailored to specific industries. The solutions can be combined modularly, integrated into existing plants and adapted to new line concepts. For mineral wool production, this means: inline technology that doesn't have to be retrofitted, but fits your production from the very start.

MATCONTROL HF model full-surface measurement installed above a production line

Inline weight per unit area measurement

GreCon MATCONTROL C and MATCONTROL HF detect variations in basis weight directly during production. MATCONTROL HF also monitors material distribution across the entire width at high resolution, detecting foreign objects and anomalies such as hot spots and wet spots. Real-time data helps stabilise upstream processes.

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Inline Moisture Measurement

GreCon MOISTURECONTROL continuously measures moisture content during mineral wool production, eliminating delays associated with sampling. Real-time measurements enable targeted optimisation of dosing, drying and curing processes, supporting energy-efficient production.

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Inline Thickness Measurement

GreCon THICKNESSCONTROL continuously measures the thickness of mineral wool mats with high precision. Deviations are detected immediately, allowing pressing and consolidation parameters to be adjusted quickly. This helps maintain consistent product quality.

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Workers display holographic data in factory hall

What missing measurement data really costs in mineral wool production

Inaccurate or incomplete measurement data in glass and stone wool production rarely adds up to a single problem. It leads to scrap, complaints and unplanned downtime, with consequences that reach far beyond the individual production line.

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

Operational consequences
Unstable processes, frequent readjustments, overloaded quality control.

Strategic consequences
Hard-to-predict production output, lower competitiveness.

The cost of inaction is high. For the production of stone and glass wool, reliable measurement technology is not a convenience, but a strategic prerequisite for stable processes.

Mineral wool on production line
Uneven fibre distribution during mat formation can compromise the quality of rock wool and glass wool, making continuous process monitoring essential.

Challenges in stone and glass wool production

In stone and glass wool production, conflicting requirements meet: the material is light and voluminous, while the process is highly dynamic and characterised by high line speeds, thermal influences and complex material movements. Sample-based checks reach their limits here. What is needed are robust systems that work directly in the process.

  • inhomogeneous material distribution due to uneven fibre deposition
  • moisture fluctuations caused by irregularities in mat formation and in binder application
  • reliable detection of foreign bodies such as hot spots, wet spots and chewing gum before they cause faulty batches
  • switch to bio binders (more moisture in the process, higher temperatures in the curing oven, increasing fire risk)
  • limited access to measuring points in thermal and mechanical process areas
  • fast process reactions that require continuous measurement
  • delayed laboratory analyses as the sole basis for decisions

Uncontrolled scatter, incalculable risk

The risks in mineral wool production are not theoretical. They occur every day, often go undetected and cause considerable costs. This is exactly where measurement technology solutions from Fagus-GreCon make the difference.

Fagus-GreCon for noticeable cost savings and verifiable product quality

GreCon measuring systems create the data basis for efficient, reproducible and stable insulation plants. Measurement takes place inline and integrated into the process, at the point where fluctuations can still be corrected. This makes the production of mineral and stone wool predictable instead of reactive.

Your added value with Fagus-GreCon

Where measurement data is missing, costs arise. Where it is consistently available, control arises.

  • More efficient use of material and energy
  • Fewer manual interventions during ongoing operation
  • Targeted, controlled interventions in production
  • Precise measurements for higher product quality
  • Consistent quality across the entire line
  • Fewer customer complaints thanks to early fault detection
Mineral Wool on a roll.
Fagus-GreCon supplies the measurement technology that gives you a decisive advantage in the production of insulation materials.

Glass and stone wool production: Frequently asked questions

Bulk density describes the weight of mineral wool relative to its volume and is determined according to DIN EN 1602 by weighing a defined sample. Depending on the product, it usually ranges between 60 and 120 kg/m³, and for some applications below or above that.

Continuous basis weight measurement shows how evenly the mat is built up across its width and length. Deviations are noticed early, so process parameters can be adjusted in a targeted manner. This saves raw materials, energy and costs in mineral wool production.

GreCon measuring systems can be integrated into existing plants. They adapt to established line concepts as well as to new production plants. No fundamental retrofit is required.

In stone wool production, mineral raw materials and recycled material are melted in a cupola furnace at around 1,500 °C. The liquid rock melt is then fiberised using a spinning or nozzle-blowing process and processed with binders into an insulation mat. Fluctuations in material distribution, moisture and thickness already arise in this phase. Continuous process measurement makes these deviations visible before they affect the finished mat.

Mineral wool is the umbrella term for two material groups: glass wool and stone wool. They already differ in their raw materials. Stone wool is made from volcanic rock such as basalt, diabase or dolomite, while glass wool is mainly made from recycled glass, sand and limestone. This also affects the material properties: stone wool offers higher bulk density and better fire resistance, while glass wool is lighter and more flexible; a difference that is decisive when choosing the right insulation material for each application.

In mineral wool production, hot spots (accumulations of glass or stone melt), wet spots (accumulations of binder) and chewing gum (binder lumps) are foreign bodies in the mat. GreCon MATCONTROL HF analyses the material distribution in real time using full-surface, high-resolution X-ray technology, detecting fluctuations and defects before they become a problem.

Bio binders are binders based on sugar or lignin and require more moisture in the production of glass and stone wool. To ensure that the wool still dries and cures at the same output, the temperature in the curing oven rises. This makes moisture measurement in mineral wool production particularly important. At the same time, the fire risk in and around the furnace increases. Fagus-GreCon also offers solutions for preventative fire protection in this area with its intelligent, next-generation fire protection concept.

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Which solution fits your production?

Every system has its own specific requirements in terms of material distribution, moisture content and foreign object detection. Let’s discuss how you can optimise the processes involved in mineral wool production. Our measurement technology experts look forward to hearing from you and arranging a no-obligation initial consultation.

We look forward to hearing from you.

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