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Why Sto Verotec remains committed to GreCon thickness measurement

Case Study – GreCon THICKNESSCONTROL

  • Publicado 6 de agosto de 2026

Verotec has once again chosen GreCon

The new GreCon thickness measurement system is designed to reliably identify the recurring deviations in panel production at Verotec. It soon becomes apparent that the measurement system not only ensures product quality at Verotec, but also offers the panel manufacturer a number of further benefits.

Thilo Schwarz

Given our positive experience with the first project, we decided very, very quickly to work with Fagus-GreCon on the second project as well.Project Engineer at Verotec GmbH
THICKNESSCONTROL LT thickness measuring system with two measuring heads and non-contact measurement using laser beams.
The THICKNESSCONTROL LT thickness measuring system determines the thickness of solid, soft and moist materials using non-contact measurement with laser beams.

Measurement problems and a reliable solution

As part of the Sto Group, Verotec develops and manufactures lightweight mineral building boards and moulded elements for façades and interiors at its Lauingen site. Just before the finished panels are de-stacked, a crucial quality decision is made: is the thickness within the specified tolerance – or must the panel be removed from the regular production flow?

Background:

In a production line set up in 2018, the plant engineer initially opted for a laser-based, non-contact thickness measurement system. A laser positioned above the panel and another below were intended to measure the material thickness. However, it soon became apparent in day-to-day production that temperature fluctuations and the dusty environment were affecting the measurements.

Over an extended period, Verotec tested various sensors and sensor manufacturers. However, this did not satisfactorily resolve the recurring deviations.

Whilst the sheet manufacturer was trying to stabilise its laser measurement system, a GreCon thickness measurement system had already been operating reliably at the same company for almost 20 years. Returning to this tried-and-tested technology was therefore just a decision away – and that is exactly what happened.

Today:

The implementation of the next GreCon thickness measurement system will not only resolve the measurement problems described – the measurement system is also set to offer further benefits for the sheet manufacturer.

The measurement result is decisive

Since September 2025, the new GreCon thickness measurement system has been in operation immediately prior to the stacking of the finished panels. It checks, whilst production is underway, whether the specified thickness tolerances are being met.

This ensures that products falling outside the defined quality parameters do not enter regular sales. At the same time, the option remains to use the material for other purposes, depending on the deviation.

The result: Verotec ensures product quality whilst also making targeted decisions on how material that falls outside the main specification can be reused.

If there are any discrepancies, the process is triggered automatically:
1
Recognise

The system identifies plates that are outside the tolerance range.

2
Send

The measured values are sent directly to the higher-level control system.

3
Eject

Affected sheets are automatically stacked separately.

Accurate measurement, reliable adjustment

One thing is clear: dust and temperature fluctuations must not disrupt quality control. This is precisely what the GreCon thickness measurement system is designed for.

It offers three specific advantages:

  • Stable measurement values even under demanding production conditions 
  • Reliable detection of slabs outside the tolerance range 
  • A reliable data basis for quality assurance and process adjustment 

To achieve this, the shift supervisor reads the values from the system and adjusts the press manually if necessary.

How THICKNESSCONTROL works

GreCon offers two measuring principles: contact (RT) and non-contact (LT/LC/SC). In contact-type systems, pairs of rollers mechanically measure the material thickness. In non-contact variants, laser beams scan the top and bottom surfaces simultaneously. All systems are designed for high cycle rates and continuous industrial operation.

Calibration, wear indication and temperature compensation are integrated. The systems require minimal maintenance and continuously record data for automatic press control or quality documentation.

System variants for every production scenario

  • RT: Robust roller systems for use downstream of sanding or sawing units. Ideal for traditional wood-based panels or sheet-like materials with a hard surface.
  • LT / LC: Non-contact laser cross-beams for continuous thickness measurement. Suitable for continuous materials, web materials and panels.
  • SC: Special design for maximum precision with very thin materials (e.g. films, rubber, non-wovens).

Which thickness measurement method is best suited to your production?

Let’s discuss your process – we’ll find the best solution to ensure consistent quality and keep costs to a minimum. Our measurement technology experts are on hand to provide comprehensive advice.
Get in touch – we’ll help you make your production more efficient!

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Save ten minutes per shift

In addition to the improved measurement quality, there is another tangible benefit in day-to-day operations: with the laser measurement system previously used, a calibration block had to be inserted by hand and the system manually calibrated once per shift.

The GreCon thickness measurement system, on the other hand, calibrates itself automatically during operation. This eliminates that step – and, according to Verotec, saves the company around ten minutes of working time per shift. At the same time, it reduces the amount of manual work required at a quality-critical stage in the process.

Measurements that are accurate and reliable

As well as providing reliable measurements and reducing the need for manual work, the system creates a robust data foundation for quality assurance.

The panels produced are marked with the date and time. Should a complaint arise at a later date, Verotec can trace the product or batch in question back to a specific production period and compare it with the stored thickness values.

In this way, thickness measurement not only informs decisions during the ongoing process; it also provides the necessary transparency when a product is already with the customer and it is necessary to trace the actual values that were present during production.

A tailored service

The new thickness measurement system had to be integrated into an existing control room system dating from 2018. As this system was unable to process the intended interface communication directly, a bespoke solution was required.

The result: a tailor-made end-to-end solution, tailored to the plant, the process and the existing infrastructure – from technical clarification through to commissioning.

GreCon did more than just the installation:
1
Interface updated

The communication has been ported to the existing control environment.

2
Process integrated

The measuring system was integrated into the existing infrastructure without any major modifications.

3
Installation conditions taken into account

Any potential production waste has already been factored into the planning.

Thilo Schwarz, project engineer at Verotec GmbH

A solution that really works

How well a solution performs in everyday use is often demonstrated not by a review, but by the next investment. Based on the positive experience with the first system, Verotec had already placed an order for a second GreCon thickness measurement system by June 2026.

It is intended for a further production line, where Verolith®- and perlite-based panels will be measured in future.

This decision confirms more than just the measurement quality. Verotec also rates its collaboration with GreCon highly:

  • Precise technical implementation 
  • Smooth project management 
  • Reliable installation and commissioning 
  • Pleasant collaboration throughout the project

As well as thickness, weight is also important

With this second system, Verotec is expanding its quality assessment to include an additional parameter. The plan is to integrate an existing plate scale.

In future, thickness and weight are to be assessed together:

  • Measuring thickness 
  • Recording weight 
  • Derive surface weight or average density 
  • Detect insufficient compaction at an earlier stage 

This is particularly relevant because insufficient compaction can compromise the stability of the board. The combination of thickness and weight data therefore provides an additional basis for a more informed assessment of board quality immediately before stacking.

Benefits at a glance

As well as providing consistent measurements and reducing the need for manual work, the system creates a robust data foundation for quality assurance and offers further benefits:

  • reliable thickness measurement despite dust and temperature fluctuations 
  • automatic detection and rejection of items outside tolerance 
  • traceable measurement data for quality assurance and complaints 
  • around ten minutes less manual effort per shift 
  • clear separation between different quality grades 
  • Prospective correlation of thickness and weight for density assessment 

Download the case study as a leaflet here:

Case Study - STO Verotec - GreCon THICKNESSCONTROL
199 KB, PDF

About Verotec

Verotec develops and manufactures lightweight mineral building boards and moulded components for façades and interiors. One product range is based on expanded glass made from recycled waste glass. This is used to produce, amongst other things, VeroBoard® AllStar, as well as building, façade and acoustic boards.

Another product range utilises perlite-based Verolith® to produce panels for façade and interior elements, window surrounds, profiles and three-dimensional moulded parts. These lightweight materials can be easily milled, sawn and further processed into complex shapes.

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