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Understanding and Controlling Uneven Material Distribution in Insulation Production

Inline measurement systems for reproducible product quality and stable processes

Home Measurement Technology Industries Insulation Industry

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

The production of glass and mineral wool is characterised by fluctuating airflows, dynamic fibre formation and thermal variations. Deviations in material distribution, moisture or thickness often develop gradually and propagate along the line. Without inline process data, these deviations remain unnoticed for a long time and affect energy consumption, homogeneity and consistent quality.

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

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

In many insulation production facilities, key parameters such as basis weight, moisture or density are still not monitored continuously. Acquisition often takes place through sampling or delayed laboratory analysis. As a result, the transparency required to operate processes in a stable, resource‑efficient and reproducible manner is lacking. The consequences become apparent in increased material consumption, energy losses and variable product quality.

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

Insulation production requires continuous monitoring of key parameters such as material distribution, moisture and thickness. Inline measurement technology delivers precise real‑time data, enables targeted process adjustments and supports stable, energy‑efficient and reproducible production.

Inline Basis Weight Measurement

GreCon MATCONTROL HF monitors basis weight almost across the full surface and with high resolution. The system detects density deviations, structural irregularities and foreign objects directly in the process. Real‑time data stabilise upstream conveying and cleaning processes by identifying anomalies before they affect subsequent steps.

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Inline Forming Optimisation

The segmented SCALPER corrects uneven material distribution through precise, segment‑based removal. Using measurement data from the upstream scanner, excess material is removed exactly where required. This leads to more homogeneous mats, more stable edges and reduced raw material usage.

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Inline Moisture Measurement

GreCon MOISTURECONTROL measures moisture continuously and without sampling delays. Values are provided in real time, enabling direct control of drying, dosing and curing processes and contributing to energy efficiency and material consistency.

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Inline Thickness Measurement

GreCon THICKNESSCONTROL continuously and precisely records the thickness of the insulation mat. Deviations become visible immediately, allowing rapid adjustment of consolidation or press parameters. This supports consistent serial quality and reduces reworking.

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The future of industrial measurement technology

“Increasing process speeds, tighter tolerances and rising cost pressure elevate the demands placed on data quality. Inline measurement technology is evolving from a control instrument into a control‑relevant information system. Modern production lines require continuous real‑time data to automatically adjust process parameters, minimise energy consumption and reliably achieve quality targets. Measurement technology therefore forms a central foundation for data‑driven, efficient and robust production environments.”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, irregularities in material distribution, density or moisture 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 Insulation Industry

Insulation products such as glass and mineral wool are lightweight, voluminous and highly dependent on airflow. Continuous formation of a homogeneous mat is a significant measurement challenge. High line speeds, thermal processes and complex material movements require robust measurement systems that operate more reliably and closer to the process than sampling methods.

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

GreCon measurement systems deliver the data needed to operate insulation plants efficiently, reproducibly and stably. Measurement takes place inline, continuously and integrated into the process – exactly where deviations arise and can still be controlled.

Supported measurement and optimisation tasks

  • Thickness measurement
  • Moisture measurement
  • Density measurement
  • Basis weight measurement
  • Bulk density profile
  • Fibre measurement
  • Forming optimisation
  • Early gap detection
  • Emission determination
  • Edge inspection

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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