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Mineral and Stone Wool Production

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

In mineral wool production, faulty batches rarely appear overnight. They start with a small fluctuation in material distribution, moisture or thickness that nobody notices until it runs through the entire production. Fagus-GreCon supplies the measurement technology that detects such fluctuations directly in the line. For less scatter loss and fewer unplanned downtimes.

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, moisture and thickness; usually gradual, rarely immediately apparent. Along the line, these effects add up and affect energy consumption, homogeneity and consistent quality alike.

Stone 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 stone wool production: Little control, high costs

In many insulation plants, key parameters such as basis weight, moisture or density 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.

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

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 Basis Weight Measurement

GreCon MATCONTROL HF monitors the basis weight in mineral wool production almost across the full surface and with high resolution. The system detects density deviations, structural irregularities and foreign objects directly in the process. The real-time data stabilises upstream conveying and cleaning processes by detecting anomalies before they affect subsequent steps.

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Inline Moisture Measurement

GreCon MOISTURECONTROL handles moisture measurement in mineral wool production 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, so consolidation or press parameters in mineral wool production can be adjusted quickly. This supports consistent series quality and reduces rework.

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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

What missing measurement data really costs in mineral wool production

Inaccurate or incomplete measurement data in mineral 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 mineral wool, reliable measurement technology is not a convenience, but a strategic prerequisite for stable processes.

finger in front of laptop points to holographic statistics

Challenges in stone and mineral wool production

In stone and mineral 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.

Typical challenges

  • inhomogeneous material distribution due to uneven fibre deposition
  • fluctuating moisture content due to variable drying conditions
  • 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.

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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 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. The density profile of the insulation mat shows that stone wool generally reaches higher values than glass wool, which directly affects compressive strength and dimensional stability.

Without continuous monitoring, typical overdosing of material is around 25 percent. Inline density measurement of stone and glass wool, together with data on material distribution and moisture, shows where reserves actually exist instead of working with precautionary safety margins. This reduces raw material consumption in stone wool production directly and measurably.

GreCon measuring systems have a modular design and can be integrated into existing plants without interrupting ongoing operations. 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.

Which solution fits your production?

Every plant has its own requirements for material distribution, moisture and density. Let's talk about how you can optimise the processes in your mineral wool production.

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