Precision as a Key to Profitability: How WayCon’s Modern Sensor Technology Reduces Discard Rates in Global Foil Production
26.03.2026
The global market for synthetic foils is faced with enormous pressure to improve efficiency. With a projected market volume of over 100 million tons by 2030 and rising raw material prices, minimizing production waste is becoming a decisive competitive advantage.
In highly dynamic extrusion and stretching lines, even the slightest deviations in roller alignment can result in material losses amounting to tens of thousands of euros per hour. WayCon Positionsmesstechnik GmbH addresses this problem with the MXI51 magnetic tape system, a solution that is ideally suited to the complex requirements of the film industry.
In large-scale industrial foil production, web tension is the critical factor. Roller systems controlled by separate electrical adjustments must operate in perfect synchronization to ensure uniform stretching of the material. Even misalignments in the micrometer range can lead to inconsistent foil thicknesses or dangerous web breaks. Modern sensor systems help optimize production processes and reduce the need for manual monitoring of the equipment. This saves costs and reduces production waste. This is where the MXI51 magnetic tape sensor comes in. While conventional measuring systems often reach their limits in the dusty environment of an extrusion line, the MXI51 operates completely wear-free based on a magnetic measuring principle. With an extremely fine resolution of up to 0.5 µm, the system detects positional differences between the lifting columns in real time. This information enables optimal synchronization, making it easy for the operator to manage the positioning of up to three adjustment units. A key economic advantage is the robustness of the technology.
In synthetic material processing, fine abrasive particles are often generated that can blind optical sensors. Thanks to its die-cast zinc housing and IP67 protection rating, the MXI51 is fully protected against these environmental influences. For plant operators, this means a significant increase in OEE (Overall Equipment Effectiveness), as unplanned downtime for sensor cleaning or recalibration is eliminated. Technical integration has been designed to be as flexible as possible: The system supports travel speeds of up to 25 m/s and delivers standardized signals (TTL or HTL) that can be processed directly by the PLC. By eliminating the need for mechanical coupling of the lifting columns, system integrators also gain valuable installation space and reduce the complexity of the overall design. In an industry where profit margins are closely linked to material efficiency, precision is not a luxury but an economic necessity. With the MXI51, WayCon offers a measurement sensor system that bridges the gap between high-speed production and micrometer accuracy.
For technical information about the MXI51 magnetic scale, please visit the data sheet MXI51.
You can find our selection of magnetic scales on our product page for magnetic scales.
