Web Gauging Systems: Improve Productivity & Profits
Turnkey solutions for every industry.
Reducing waste, improving production processes, and maximizing raw material use. These are mission-critical business goals for this year and probably every year before. It’s time to invest in the gauging system technology you need to achieve your efficiency goals.
Quad Plus engineering experts understand your machines and processes. We deliver customized solutions with minimal downtime.
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What is Web Gauging?
A gauge system is designed to precisely measure materials moving through your production line’s continuous web handling processes. Advanced sensors measure thickness, basis weight, and other material metrics in real time. Automated control systems can then make minor adjustments to optimize production and save energy and materials.
The result is finished products that meet your strict quality standards. The process will consume less material and produce less waste. Web gauging systems support a variety of manufacturing applications. Industries served include nonwovens, extrusion, converting, and building materials.
Main Components of Web Gauging Systems
A web gauging system works by comparing a measurement to a set standard. The user will be shown whether the measurement is smaller, larger, or within range. Three main components are used to achieve this:
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How Web Gauging Systems Save You Money
Web gauging systems are designed to improve your operations. Boost profits using long-term and real-time data on thickness, basis weight, density, moisture percent, and coating thickness.
Examples of Web Gauging Systems at Work
Continuous measurement and automated controls benefit manufacturers across industries. Here are several examples of applications for web gauging systems.
Measuring sheet thickness improves adherence to quality standards. It also demonstrates compliance with industry and regulatory standards.
Measurements help evaluate line performance to optimize process control, boost productivity, and reduce scrap.
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Innovative Web Gauging Systems Technology
Choosing the right web gauging system technology for your operation depends on your production lines, input material, and end product. By selecting the best frame, scanner, and software for your goal.
Scanning Frames
I-Frame: The compact I-Frame design is used in applications requiring only a single-sided gauging sensor. For example, multi-layer thickness, moisture percentage, and coating thickness. To ensure proper alignment, the rails can be cut by a CNC machine.
O-Frame: The O-frame is used in applications requiring dual-sided gauging sensor technology. For example, beta transmission and X-ray transmission. The top and bottom rails of O-frames are optically aligned to each other to ensure precision alignment.
C-Frame: The dual-sided sensor mounted in a C-shaped frame. Common in applications requiring periodic scanner removal. Examples include X-ray systems on hot rolling mills or ERS (external reference surface) configurations.
Slim I-Frame: The single-sided slim frame is used in applications where a small, lightweight frame suits the customer’s needs. This frame was designed to be just slightly wider than the sheet width.
Compact O-Frame: The dual-sided compact frame supports transmission sensor applications. It fits small machine footprints and simplifies service and maintenance.
Sensor Technology
Our engineers will help you to determine which gauging sensor is best for your application.
Sensors provide multiple measurements every second to assess these product dimensions:
- Thickness
- Multi-Layer Thickness
- Single Sensor Simultaneous Thickness, Basis Weight, and Density Measurement
- Basis Weight
- Density
- Coating Thickness
- Moisture Percentage
- Delamination
We provide expert help choosing the sensor technology that’s right for your application:
- Terahertz
- Ultrasonic
- mmWave
- Near Infrared
- BETA (Sr-90 and Kr-85)
- X-Ray
- Microwave
- Color Detection
- Laser
Software & Reporting
Get the most from your production lines with the best web gauging software available today. We also provide the training you need to maximize your results.
Modern software uses established control algorithms. The goals are to reduce startup waste, run closer to targets, and reduce material consumption.
How does it work? The software interprets data readings from the scanning frame. Operators are then presented with easy-to-understand information from the current production batch. This enables real-time identification of production issues while the line is running. Data is stored for further reporting and analysis after production.
Intuitive reporting tools allow you to filter data down to the control zone. Scans can also be compared to identify products that do not meet your quality standards. That way, you can pull them before they are sent out. Plus, real-time displays and reports can be customized. You can stay focused on the data that matters most to your operations.
How to Implement Web Gauging Systems in Your Facility
To assemble your web gauging system, you need more than hardware and software. You also need a partner who will be available from initial planning to after-installation support.
We are a team of qualified experts and technicians committed to making your web gauging system a success. We provide the support team needed to select and install the best system to meet your needs. We also help train your staff so you get the most out of your system.
Ready For a Web Gauging System Demo?
Are you interested in how web gauging systems work but still have questions? Our expert technicians are available to dive deeper into the details. We are ready to discuss your production and gauging application needs.
Seamlessly integrate advanced web gauging scanner technology into your existing control system. Enjoy expert support to determine the right technology for your application. We will configure the frame for optimal performance and install the web gauging sensors.
Let’s work together to build your new web gauging system. We will help you improve production while realizing a tangible return on your investment.
Frequently Asked Questions
The typical payback period after investing in a web gauging system is about a year.
Manufacturing productivity is the amount of output from a given amount of input, considering both the quality and the speed of the output.
A web gauging system is the key to improving productivity. It does this through increasing efficiency and reducing waste. Continuous measurements enable adjustments before costly waste and scrap are generated.
