Running an extrusion line without a proper measurement system is like bleeding money. Scrap rolls, off-spec product, rework, manual checks, and increased labor all eat into margins. Meanwhile, competitors are running tighter tolerances, reducing waste, and proving it with data. From both a cost and quality perspective, the web gauging system is one of the most critical components on an extrusion line.
That’s why Scantech has become the partner of top producing plants and highest regarded OEM line builders. With over 30 years of innovation and more than 7,000 systems installed globally, Scantech’s measurement and control systems are guaranteed to give you the best return on investment (ROI). Precision, traceability, and automation are no longer optional in today’s Industry 4.0 manufacturing environment: they are the competitive edge.
Scantech systems deliver a comprehensive range of measurement data: thickness, basis weight, density, moisture content, and additive concentrations (e.g., TiO₂, BaSO₄, CaCO₃). For quality-critical lines, 100% defect detection via integrated vision systems is also available. View the video below to see Scantech’s capabilities for different extrusion processes.
⚙️ Why Scantech’s Sensor Technologies are Best-in-Class
Scantech’s founders pioneered the use of x-ray gauge measurement for thin film in 1992, and for good reason. It is the most accurate and versatile measurement solution available for web processing applications when compared with outdated radioactive technologies.
Key Advantages of Scantech’s X-Ray Sensors:
- ✅ Non-radioactive, safer, and more accurate than gamma or beta sensors
- ✅ No source replacement nor costly disposal required
- ✅ Unaffected by web flutter, color, or print
- ✅ Precision up to 0.03 µm and repeatability of 0.02 µm
- ✅ Immune to many material composition shifts
- ✅ Requires no water cooling thanks to low-power tube design
When x-ray isn’t the ideal fit or when multiple measurements are required, Scantech offers a range of alternative sensor technologies. These include: laser triangulation, laser shadow, confocal, infrared, and ultrasonic sensors. As with x-ray, these sensors have been carefully engineered to deliver high-precision, non-contact measurement.
This adaptable sensor platform supports diverse material types and provides critical measurements such as thickness, basis weight, density, moisture levels, and additive content. Want to learn more about the pros and cons of each individual sensor technology in more depth? Reference this article here.
🧰Engineered Scanners That Go the Extra Mile
Great sensors need robust mechanical systems to match. Scantech’s scanners are engineered for industrial environments and deliver:
- Built-in air cooling connector for high-temp environments
- Air curtain fan around the sensor beam to maintain temperature
- Auto-compensation for air temperature, pressure, humidity—without stopping the sensor heads.
- Maintenance access from one side only—no need to crawl behind equipment
- Hazardous Purge (Class 1 / Div 1) ready for volatile atmospheres
- Plug-and-play setup: 120V power + Ethernet = simple installation
💻 Control Software That’s Built for Operators (and Industry 4.0)
Scantech’s HMI and control software makes real-time monitoring simple:
- Intuitive interface with easy navigation and modern graphics
- Customizable charts, polar profiles (blown film), MD trending graphs, etc
- Auto-generated reports by roll, shift, or batch: Excel & PDF ready
- TREX Cloud: web-based platform for centralized reporting & analysis
- Smart Maintenance Tool: Diagnose issues without needing a voltmeter
- Seamless OPC-UA integration to main extrusion line controls
- Same-spot measurement for multi-scanner lines
🔧 Die Bolt & Line Speed Control That Actually Works
With Scantech’s optional Automatic Bolt Controller and I/O Panel, your system can automatically:
- Map and adjust die bolt positions in real time with any die
- Instant visibility into which die bolts are adjusting and by how much
- Detect failed die bolt heaters automatically
- Regulate extruder RPM or line speed based on thickness variation
🚀 Driven by R&D and Backed by Culture
Scantech isn’t just an equipment supplier. It’s a company driven by a team that is passionate about the technology. As a privately held company, Scantech reinvests over twice the industry average into research and development. Scantech’s ongoing R&D advancements continue to deliver real value to customers, resulting in the sale of over 1,000 systems in 2024 alone and strengthening its role as the preferred partner for leading extrusion OEMs.
More than technology, Scantech fosters a culture of innovation and collaboration. Their annual R&D Days event brings together team members from around the world to share knowledge and accelerate improvements. Investment in employees is paramount to Scantech’s success. 👇 Watch the video from R&D Days 2025 to hear what it’s all about!
📌 Why Process Engineers & Plant Managers Choose Scantech
When it comes to quality, uptime, and long-term ROI, Scantech measurement systems deliver:
- 🏭 Trusted by the world’s top extrusion OEMs
- 🧪 Unmatched precision with a complete sensor portfolio
- 🧰 Systems built for both harsh and cleanroom plant conditions
- 📉 Reduced scrap, less downtime, and better product quality
- 👨🔧 Operator-friendly software and remote support
- 🌍 7,000+ systems installed in over 60 countries
📞 Take the Next Step
Whether you’re planning a critical upgrade or just want to talk shop, reach out to start a conversation. After all, how much is your outdated or non-functioning measurement system really costing you?
📄 Gather technical specs & request a quote
📬 Send film or sheet samples for evaluation & testing
💬 Connect today to discuss your project
Founder, Gauge Advisor LLC