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Material Distribution & Foreign Object Recognition

DIEFFENSOR weight per unit area x-Ray scanning 100% of the production run

The GreCon Mat Scanner DIEFFENSOR with X-ray technology defines material distribution using weight-per-unit-area measurements. The scanner measures the whole product by continuously measuring across the entire production width.

Exact graphical and numeric representations enable the operator to adjust the forming process to achieve consistent quality while the use of material and energy is optimized.

Continuous monitoring of the weight distribution provides for an optimal flow of production and prevents unequal weights in the process. Adjustments to the production process are based on real-time measuring data displayed on the visualization computer. Detailed data reports can be produced for extensive evaluation of production processes over the long term.


Materail distribution is clearly display using Weight Per Unit Area measurments accross the whole production width.Clear display of material distribution across the production width.

The GreCon Mat Scanner DIEFFENSOR measures volumetric or density differences and can also recognize foreign objects in the material or product. The DIEFFENSOR is able to identify high density metallic and non-metallic foreign objects. For example glue lumps, fiber lumps, hot and wet spots, as well as plastic and aluminum parts.

The DIEFFENSOR recognizes the form and mass of a foreign object and stores this image in 3-D graphics for evaluation at a later time. One example is hot spots, which are identified as foreign objects during the production of fiberglass and rock wool. These hot spots can cause damage to the product and the production line.

During the production of chipboard, high density foreign objects can cause irreversible damage to the steel belts of a continuous press. Likewise, cavities or bubbles during plastic production can also be recognized by the DIEFFENSOR.

Foreign objects, hot spots and high density areas are easily identified.Foreign objects, hot spots and high density areas are easily identified.

X-Ray Mat Scanner Measuring Principle

The DIFFENSOR is a highly developed mat scanner that measures the weight per unit area distribution of endless materials across the entire width of production.

The DIEFFENSOR uses the absorption measuring method. One or more x-ray sources are installed above the material flow. Below, the high-precision sensors measure the residual radiation that has not been absorbed by the material. The weight per unit area and the material distribution can be determined form the degree of attenuation and the specific density of the material.

Steel belt protection is another benefit of the DIEFFENSOR. Stainless steel belts on continuous press are costly to replace. While the fiber mat is being formed there are times when equipment parts, bolts, plastic or aluminum items dropped on the mat. Metal detectors will identify the metal parts and bolts but not plastic or aluminum items. These items can damage steel belts creating dents or cracks that will transmit the flaw onto every panel the damaged area come in contact with. The produces defective panels that need to be identified and sorted out from the good quality product. With the DIEFFENSOR it detects foreign objects and triggers a signal to a mat discharge machine that will prevent such hazards from entering the press.

X-ray sources above the material flow. Below are the high-precision sensors.X-ray sources above the material flow. High-precision sensors below.

Material Distribution & Foreign Object Recognition Software

The core of the software is the visualization. It allows the configuration of the measurements and because of its clear structure, offers a quick view of all information in numerical form as well as diagrams.

  • curve
  • bar graph
  • 3-D representations

Deviations from the regular production process are clearly indicated and enable the operator to intervene quickly and effectively. Detailed reports can be produced for additional analysis

1) Lateral distribution of weight per unit area in 3-D.     2) Lateral distribution of weight per unit area in 2-D.     3) Foreign object detection in 3-D.

DIEFFENSOR screen shots

Material Distribution & Foreign Object Recognition Applications

Selection of different materials measured by the DIEFFENSOR includes Chipboard, MDF, HDF, OSB, Particaleboard, Mineral Wool, Fiberglass, Gypsum, Plastics, and Insulation.
Click to enlarge.

    Wood Based Panel Industry:
    the DIEFFENSOR is used before the press to measure weight per unit areas and material distribution, and to protect the steel belts for:
  • Particleboard
  • MDF
  • HDF
  • OSB

Insulation Industry
Hot spots can cause severe damage to production equipment due to delayed heat release. Missing material can lead to expensive customer complaints or reduced quality. With High-resolution evaluation, the DIEFFENSOR is able to detect foreign objects, such as glue lumps, hot spots, wet spots as well as metallic and not-metallic elements. Even areas that are to light, such as air voids or missing material, can be detect.

    Rock Wool Plants:
  • in the primary mat for weight per unit area measurement of material distribution and foreign object detection
  • in the secondary mat before the furnace to control the pendulum and transport speed in dependence of the measured weight per unit area and for foreign object detection.
  • in the secondary mat after the furnace for quality control, foreign object detection.

    Glass Wool Plants:
  • after the furnace for quality control, foreign object detection, and hot spot detection

    Wood Wool Plants:
  • before the dryer for quality control

    Other industries:
  • in gypsum plants after drying for quality control
  • for transformer board in the quality line for foreign object detection
  • for plastics to detect air void and to measure the weight per unit area

Material Distribution & Foreign Object Recognition Technical Info

  • Measuring range: up to 50kg/m²
  • Product speed: 0 to 180 m/min
  • Product height: 0 to 500 mm
  • Product width: 0 to 4,000 mm