DSG-Canusa GmbH, part of the global Mattr group, is one of the world’s leading manufacturers of heat-shrink tubing and related solutions. The company serves a wide range of industries, with a strong focus on the automotive sector. With more than 300 employees and a strong manufacturing site and engineering base in Rheinbach, Germany, DSG-Canusa continuously invests in technologies that ensure consistent product quality, process efficiency, and long-term competitiveness.
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RAYEX®S at DSG-Canusa’s Rheinbach manufacturing site |
For over 15 years, DSG-Canusa has relied on Zumbach Electronic AG as a trusted partner for inline measurement and quality control. What started with laser-based diameter measurement has developed into a comprehensive solution for real-time monitoring of outer diameter, geometry, inner diameter, and wall thickness. This provides deeper process insights and measurable productivity gains.
From Outer Diameter Control to Inline Wall Thickness Measurement
Initially, DSG-Canusa used ODAC® laser measuring gauges to control outer diameter and geometry during production. While this enabled reliable inline monitoring of external dimensions, there was no inline solution for measuring wall thickness. As a result, operators had to take frequent offline samples throughout the day to verify wall thickness. This process was time-consuming and increased the risk of producing scrap before deviations were detected.
To improve process transparency and reduce manual inspection, DSG-Canusa began evaluating inline wall thickness measurement solutions. After testing several competing systems, ZUMBACH’s proven technology, the long standing partnership, and highly positive test results led to the decision to implement the RAYEX® S X-ray measuring system.
Real-Time Measurement with RAYEX® S
Today, DSG-Canusa operates two RAYEX® S 50 X-ray measuring systems installed in extrusion lines for heat-shrink tubing. These systems provide real-time measurement of inner diameter and wall thickness, allowing continuous monitoring of two layers inline — well within the system’s capability of measuring up to four layers.
The impact has been significant:
- Reduced need for manual sample checks, freeing up operators for higher-value tasks
- Faster response to process deviations
- Lower scrap rates through early detection of out-of-spec material
- More stable and repeatable processes, particularly during startup and product changeovers
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Inner diameter and wall thickness measurement provided by RAYEX®S |
By significantly reducing manual offline measurements, DSG-Canusa has lowered workload and interruptions while gaining greater confidence in consistent product quality throughout the production process.
Multi-Stage Quality Assurance with ZUMBACH Systems
In addition to RAYEX® S, DSG-Canusa continues to use ODAC® laser gauges at the end of the line as an additional quality control step. KW lump and neckdown detectors further support defect detection by identifying local diameter variations that could impact product performance.
Together, these systems form a comprehensive inline quality assurance concept, covering critical parameters from extrusion to final inspection.
Supporting Current and Future Production Requirements
With ZUMBACH’s inline laser and X-ray measurement technology, DSG-Canusa has taken an important step toward more data-driven, efficient, and future-ready production. Real-time monitoring of critical dimensions not only ensures current quality standards but also enables further automation, process optimization, and digitalization initiatives.
The successful integration of RAYEX® S into an existing production environment demonstrates how targeted technological upgrades, combined with a reliable partnership, can deliver tangible operational benefits.
Pictures source: ZUMBACH
