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Critical measurement points in the transformerboard production process

Understanding the key challenges in production and quality parameters

Where the production process requires continuous, non-destructive testing at various points

During the manufacturing process for transformer boards, a cellulose pulp suspension is formed and dewatered to produce a continuous sheet.
The board is then compacted to the required density using multi-stage or continuous-action presses. Curing ovens and dryers remove residual moisture, and the boards are finally cut crosswise, calibrated and sanded to their final thickness. During this process, there are several critical measurement points that must be taken into account:
Before the press: Metallic or dense inclusions can trigger partial discharges and catastrophic dielectric failures during operation. 
After the press: Residual moisture and thickness variations following pressing and drying impair dielectric strength and mechanical dimensional accuracy.
After drying and cutting: Internal cracks between the layers are not visible from the outside but must be detected and sorted out.

If the customer's goal is simply to prevent damage to downstream equipment, a metal detector may be sufficient. However, if the customer requires reliable quality control, the localisation of contaminants, the detection of non-metallic inclusions and process transparency, our systems offer significantly greater added value.GreCon Engineering

Manufacturers of transformerboards are under pressure to increase their production capacity whilst ensuring top-class quality

The demand for transformerboards is rising rapidly due to grid expansion, renewable energy projects, electrification and investment in data centres. Manufacturers are finding it difficult to expand their capacity whilst maintaining delivery reliability and product quality. Furthermore, transformerboards play a crucial role in the safety of power transformers. Even minor deviations in the manufacturing process can compromise the reliability and service life of the transformers.

60 %

Material waste can be generated during conventional production of complex cellulose-based transformer insulation components

up to 6 %

maximun thickness shrinkage permited for several pressboard grades

± 5 %

typical thickness tolerances make every fraction of a millimetre count

Solutions and concepts

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

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

Inline Basis Weight Measurement

Using full-surface, high-resolution X-ray technology, MATCONTROL HF analyses material distribution in real time – detecting foreign objects, fluctuations and errors before they become a problem. Ideal for preventing belt damage and process disruptions.

APRENDE MÁS

Inline Moisture Measurement

GreCon MOISTURECONTROL measures moisture continuously with an optical sensor. Light in the NIR range is used for this purpose, which is absorbed by the moisture in the material. Values are provided in real time, enabling direct control of drying, dosing and curing processes and contributing to energy efficiency and material consistency.

APRENDE MÁS

Inline Thickness Measurement

GreCon THICKNESSCONTROL determines the thickness of solid, soft and moist materials using touch probe or non-contact measurement with laser beams. Deviations become visible immediately, allowing rapid adjustment of consolidation or press parameters. This supports consistent serial quality and reduces reworking.

APRENDE MÁS

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 Transformerboard Industry

Transformerboard production requires precise process control. The sheets can have an area of more than 20 m², whilst thickness tolerances are typically ±5 % and shrinkage during drying can be as high as 6 %. Combined with long pressing and drying times, sensitivity to moisture and strict quality requirements, even minor process deviations can quickly have an impact on material consumption, productivity and the quality of the finished sheets.

Typical challenges

  • Metallic or dense inclusions can lead to partial discharges and catastrophic dielectric breakdown during operation
  • Residual moisture and variations in thickness following pressing and drying adversely affect the dielectric strength and mechanical fit
  • Internal cracks between the layers are not visible from the outside, but must be detected and sorted out

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 transformerboard 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

  • Full- area X-ray for foreign-bodies and metal detection
  • Inline thickness measurement
  • Residual moisture measurement
  • Basis weight measurement
  • Material distribution measurement
  • Density profile
  • Final thickness measurement
  • Internal splits and delamination

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.

GreCon MATCONTROL installed in a production line, including monitor for the software
Thanks to flexible software, users have direct access to measurement data for an up-to-date overview of the production process.

We look forward to hearing from you.

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