Precision as a vocation – Increasing process reliability in the injection moulding industry by means of metal separators

Standardisation in foreign body inspection

Standardisation in foreign body inspection


Precision as a vocation – Increasing process reliability in the injection moulding industry by means of metal separators

Precision is a key criterion for the profitable manufacture of high-performance plastic parts. At Sola Messwerkzeuge AG, high-performance metal separators reliably help to avoid influences on product and process quality.

From attic to industrial plant

The history of Sola begins with Ing. Guido Scheyer and his colleagues Sottopietra and Latzel, from whose surnames the company’s name is composed. The first spirit levels were manufactured in the attic of a house. In the founding period wood was still the material of choice, as in many other areas. As early as 1957, however, aluminium was used as a starting product in order to improve measurement accuracy. From 1958 onwards, the company also entered into the production of plastics, initially with a mechanical injection moulding machine, which can still be seen today in the entrance area of the production hall of the Sola plastics plant. In 1969, production began in the new plant at the present-day headquarters in Götzis, Austria, where the era of the acrylic glass spirit level, whose closure by means of ultrasound was patented, also began for Sola.

In the following years, the product range was expanded to include many precision tools such as tape measures, folding rules or laser measuring instruments. Accordingly, the volume of plastic production also increased. This increasing in-house demand was supplemented by a high portion of third-party products, such as high-quality fittings for garden furniture. For this purpose, production was relocated to its own building in 2003, today’s Works 3. A total of 45 injection moulding machines with a closing force of 50 to 300 metric tons process more than 2,500 metric tons of plastics here every year. “Increasing production figures and the will to optimise have kept us constantly on our toes in recent years. The reduction of scrap and long service lives improve both the cost-effectiveness and the sustainability of our products”, says Guido Timmermans, Head of Plastics Production. Thus, Sola continues along the path taken many years ago with the first wooden spirit level to create long-term success with uncompromising precision and reliability.


Precision for measuring tools – spirit levels from the injection moulding machine

Precision for measuring tools – spirit levels from the injection moulding machine


Internal and external influences

The production of plastic parts by injection moulding is subject to various influences. Depending on the type of part to be manufactured, these have a greater or lesser impact on quality and cost-effectiveness. The ingress of foreign bodies is a major problem here, under certain circumstances both for the injection moulding process and for the finished part. Metallic foreign bodies in particular represent a relevant portion of possible impurities.

From the outside, metal impurities are introduced via the raw materials. This can take place via recyclates as well as via new material or masterbatches. Metals occur here as inclusions, or as loose parts in packaging units or tank trucks. A company’s own production environment can also be the cause of the ingress of metal parts through assembly and maintenance work, in-house comminution systems or simple inattentiveness. Metal chips, cable cores or washers are typical examples of such foreign bodies. If these parts get into the plastication unit, they can cause various problems. The most obvious is a blockage of the nozzle valve or, in the case of larger parts, even damage to the screw. As a result, this usually causes longer maintenance work and machine stops – several times per week and plant at Sola depending on the material processed.

Considered less, but still problematic, is the influence of metals in the melting process. Foreign substances influence the plastication process and can thus trigger quality problems, especially in the case of sensitive moulded parts. Finally, of course, invisibly enclosed metal particles are a threat to the structural integrity of the finished parts.


Safeguarding production with metal separators

Safeguarding production with metal separators


Reducing risks

In developing their risk minimisation strategy, ingress from the outside had to be kept to a minimum for Sola. This was accomplished by selecting high-quality suppliers with corresponding capacities in metal detection. Regular training for the personnel on the injection moulding machines, for the works engineering department and for external companies are further components for the reduction of the occurrence of foreign bodies. Despite these measures, however, the process quality that a manufacturer of high-precision measurement technology strives for had still not been achieved. A final safety measure at the machine inlet had to be found. At this installation position there are two widely used options for material inspection. One of them is magnets in different designs. However, these have the disadvantage of keeping only magnetic metals out of the system. This mainly means iron, as well as some types of formed stainless steels. However, the electronic metal separator lends itself as a solution for the reliable and automatic removal of all types of metal from the material flow.

Only one option for freedom from metals

All-metal separators for the machine intake are available from various manufacturers. They work according to the so-called “balanced-coil” principle. Following test installations, the Plastron 05 K was chosen. The appliance was produced by Mesutronic Gerätebau GmbH from Kirchberg im Wald. The compact metal separator was particularly convincing in the areas of detection accuracy and reliability. In addition, the Mesutronic employees delivered the best quality of service in the project planning, installation and commissioning phases.

“After installing the test unit from Mesutronic, we were able to significantly reduce our machine downtimes once again. The final decision was thus taken to equip the most relevant systems with metal separators”, says Michel Gorga from the Works Engineering department at Sola.

Thirteen metal separators currently protect the most vulnerable injection moulding machines. In addition to the tool-free disassembly of the ejection unit when changing materials or colours, the appliances offer a very high detection accuracy. Even fine chips or wire pieces made of stainless steel, copper or aluminium are reliably detected and discharged with minimal material loss. Thus, the two specialists for measurement technology have come together not only through the almost identical corporate colour, but also through their common claim to precision and reliability without compromise.



From the 16th to the 23rd of October 2019 we are participating in the K 2019 exhibition in Dusseldorf, the leading global trade fair for the plastics and rubber industry. On our booth 10J30 in hall 10 we will be presenting various highlights of our metal detector and separator portfolio.

In addition to proven product solutions, the new metal separator PLASTRON 05 K is our highlight at K 2019!

The PLASTRON 05 K is developed for the examination of plastic granulates, ground material and powders for metallic foreign bodies. It is used in the injection molding and extrusion industry for slow-flowing material columns. Both the detector and the ejection unit have been specially developed for this area of use. This results in top performance regarding precision, operating reliability and ease of cleaning. The system can also be used for the most diverse material temperatures and flow characteristics. Further information on the PLASTRON 05 K can be found at

Our experts on site are looking forward to your visit and to interesting conversations!

PLASTRON 05 K – Metal separator for installation on injection molding machines or extruders



Metal separation on the machine intake. The last chance becomes the first choice.

The Plastron 05 K is a new metal separator from MESUTRONIC. It was developed for the examination of plastic granulates, ground material and powders for metallic foreign bodies. It thus completes the company’s extensive range of products for injection moulding and extrusion for the application case of slow-flowing material columns. It is installed directly between feed systems such as hopper loader or mixer and the plastification unit.

Particular consideration was given to the temperature stability and detection accuracy of the detection coil. This was achieved through the use of precision milled parts and a winding support made of modern composite material.

The ejection unit impresses with absolutely reliable ejections of both bridge-forming and slumping or free-falling materials. It can also be dismantled for cleaning in a matter of seconds without tools.

The high-quality AMD 05 functions as the evaluation electronics. Apart from excellent immunity to interference, this also offers ideal communication options in the sense of digitalization.

This combination of innovation and reliability results in top performance data for precision, operating reliability and ease of cleaning. Even in the basic version the system can be used for material temperatures up to 120 °C. This offers considerably greater flexibility with the increasing use of pre-dried granulate.

MESUTRONIC Gerätebau GmbH has been producing innovative metal detection technology for the plastics industry for over 25 years. Customers all over the world are supplied with metal detectors and separators from the company’s headquarters in Kirchberg im Wald.

MESUTRONIC – Metal Detection – Made in Germany – at the FAKUMA from 17/10/2017

We will be presenting reliable metal detectors and separators over five days at the FAKUMA in Friedrichshafen. They are a must for plastics-processing companies that want to ensure product quality and protect their production machines. Visit us at Booth 6306 in Hall A6 and experience reliable and safe metal detectors and separators.


We are presenting the QUICKTRON 03 R metal separator for the examination of granulates and flakes in free-fall. The separator impresses with its outstanding price/performance ratio and its integration-friendly compactness. The device detects and separates all metals as loose parts or inclusions in the product stream.


Furthermore we are exhibiting the P-TRON 03 FM metal separator. The separator is integrated into intermittent vacuum conveying lines for the monitoring of granulates. Flexible, fast and cost-effective integration in the pipelines is possible – independent of the direction. The appliance impresses with its highly precise metal detection and is simple to operate. Uncompromising safety is supported through the mesuSafetyPack.


Our portfolio includes the METRON 05 D separable tunnel metal detector, especially for the recycling sector. The metal detector is integrated into conveyor belts, vibrating fluidslides and material chutes in order to protect production equipment. A harsh industrial environment does not prevent the METRON 05 D from achieving high detection accuracy. Its practice-oriented technology has been proven over years of use, making the detector a reliable partner in the processing of plastics.

FAKUMA – a leading trade fair for the plastics industry

More than 1700 exhibitors are presenting their international product ranges in Friedrichshafen. 40,000 trade visitors are expected to come from over 120 countries to gather information about the latest technologies in the plastics industry from 17 to 21 October 2017.

MESUTRONIC is looking forward to your visit

The MESUTRONIC team is looking forward to giving the interested trade visitors an understanding of “Metal detection – made in Germany”. Visit us at the FAKUMA in Hall A6 at Booth 6306!

Mesutronic at the K 2016 in Düsseldorf

Kirchberg im Wald. The K trade fair opens its gates once again in Düsseldorf on Wednesday, 19 October 2016. The trade fair is the absolute highlight in the industry and the starting point for trendsetting decisions for process, product and problem solutions in plastics processing.

We interviewed our product manager Jörg Pattberg about this industry highlight:

Mr Pattberg, how important is the plastics market to MESUTRONIC Gerätebau GmbH?

 JP: The plastics industry is one of our most important business segments. The roots of Mesutronic, which was founded nearly 25 years ago, lie here. Over the years both our portfolio and our network of technicians and sales specialists has grown continuously. Our high presence at the most renowned plant manufacturers and end customers in this sector proves it. And we will, of course, continue to focus on this market in future.

For product manager Jörg Pattberg is the plastics industry one of the main business segments of the MESUTRONIC Gerätebau GmbH.

For product manager Jörg Pattberg is the plastics industry one of the main business segments of the MESUTRONIC Gerätebau GmbH.

How important is the K trade fair to Mesutronic?

 JP: To be internationally successful in the plastics industry we have to be present for our customers. Direct contact is very important to us. The K trade fair is a good place, not only to meet our customers en masse, but also to generate new contacts and to show them our proven metal detection technology. Our presence began here in the founding years and we will continue in future to be present for our customers and joint exhibitors within the framework of the trade fair.

What are you expecting from the K trade fair?

 JP: Business transactions at trade fairs have receded more and more into the background in recent years, so we are focusing on communication and customer ties. That is also reflected by our new booth concept, which backs off a little from pure presentation. We see ourselves as partners and want to convey inclusion and enjoyment in contact at every level.

Mesutronic stands for innovative devices; what are Mesutronic’s plans with regard to the plastics industry? How do you stand with regard to Industry 4.0?

 JP: A very interesting development project for the plastics sector is currently in progress in the company. No further details will be available until the end of next year, however. Industry 4.0 is not a new topic for us. We made provision more than 10 years ago for the simple linking of our machines to higher-level systems, both for data acquisition and for external control options. The most diverse communication methods are available to the customer today. That’s why we see many opportunities here and consider ourselves to be ideally prepared.

Our exhibition team is looking forward to present reliable metal surch technology on the new Booth.

Our exhibition team is looking forward to present reliable metal surch technology on the new Booth.

MESUTRONIC presents reliable and safe metal detection technology at the FAKUMA 2015

Friedrichshafen/Kirchberg. The FAKUMA 2015 will once again be the meeting place for the plastics processing industry from 13 to 17 October 2015. The trade fair in Friedrichshafen has been offering a comprehensive insight into the entire spectrum of plastic technologies for over 30 years.

The detection of metal contaminants in plastic parts for the protection of production systems is also a major topic in the plastics industry. MESUTRONIC Gerätebau GmbH is a specialist in this area. The manufacturer of metal detectors and separators from Lower Bavaria will present its innovative metal detection technology in Friedrichshafen at its trade fair booth in Hall B1 / Booth 1103.In addition to further metal separators for the freefall and pneumatic conveying of granulates and ground stock, the company will present the QUICKTRON 05 RH for the examination of masterbatches.This system, which originates from the food industry, offers many advantages. Its completely colourless construction, which avoids all discolouration of the granulates, is unique in the entire industry. All plastic parts that come into contact with the product are manufactured in neutral white. Furthermore, the passage is silicone-free and extremely easy to clean without tools. Even in environments with strong interference fields, the patented PowerLine principle offers maximum precision while at the same time also preventing false alarms due to static charging of the granulate.

MESUTRONIC looks forward to welcoming numerous visitors to the FAKUMA in Friedrichshafen and to many interesting contacts and intensive discussions on the subject of “Metal detection –
Made in Germany”.

Great interest in innovative solutions in industrial metal detection Technology from MESUTRONIC

From the 05/21/2014 was the Westfalenhalle in Dortmund two days the venue for one of the most important business and information platforms in the bulk industry. The SOLIDS 2014 was with 393 exhibitors and 5,000 professional visitors as busy as ever. This trend was also reflected on the MESUTRONIC booth again. Numerous interested visitors informed themselves about the latest solutions from the device manufacturer. In particular, it was about the topics machinery protection and product quality assurance for visitors from the bulk area. For this essential important issues of a manufacturing company the MESUTRONIC Gerätebau GmbH offers, among other things, the metal separator QUICKTRON 07 RH. The inspection device scans bulk materials in free fall, high precision and is a first in terms of Hygiene. Another top unit in the industrial metal detection technology is the metal detector PTRON 03 FM from MESUTRONIC. The detector is mainly used in the plastics sector and inspects granules, flakes, regrind and virgin material in vertical and horizontal Suction Lines.