Extrusion International 1-2025

34 Extrusion International 1/2025 MEASUREMENT TECHNOLOGIE – CASE STUDY Cost Savings in the Production of Pipes S WM International, based in Richland, Philadelphia, USA, is a specialist in the manufacturing of polypro- pylene and HDPE tubes and pipes. The company relies on the UMAC ® R ultrasonic measuring system from Zumbach Electronic to maximise their manufacturing ef ciencies, whilst providing signi cant cost savings through reduced waste materials. The UMAC ® ultrasonic measuring system is a state- of-the-art solution which measures wall thickness, ec- centricity, and concentricity of tubes and pipes with unparalleled precision, with the ability to handle prod- uct diameters ranging from 0.2mm up to 400mm. The solution has been developed with a range of different transducer holders that make the UMAC ® exceptionally versatile. Integrated into the UMAC ® is the System on a Chip (SoC) unit called UMAC ® CI. This expands capa- bilities with recipe-based operation (without require- ment of manual setting manipulations based on the echo signal display), provides a 1kHz sample rate and an integrated webserver. The UMAC ® R system provides xed transducer holders, available in con gurations for 4, 6 or 8 measuring points. The ring-shaped transducer mounting xture is con gured for installation into an existing vacuum tank and integrates seamlessly into ex- isting production lines. SWM embarked upon a transformative journey with Zumbach Electronic to address a critical challenge in their polypropylene and HDPE tube and pipe produc- tion facility in Richland, Philadelphia. The traditional method of measuring products off-line with calipers was not only time-consuming but also resulted in sig- ni cant material waste and production down-time, driving up production costs, and the implementation of the UMAC ® R marked a turning point for SWM. The solution, provided by Jorge Lage at Zumbach Electronic Corp. offered fast eccentricity testing capabilities which signi cantly reduced start-up times and facilitated quicker changeovers. Real-time feedback enabled im- mediate adjustments, ensuring consistent product qual- ity and drastically reduced material waste. In its rst year alone, the UMAC ® R system delivered an impressive $40,000 in scrap savings. SWM Interna- tional’s collaboration with Zumbach Electronic exem- pli es how innovative technology can drive signi cant improvements in manufacturing processes. By embrac- ing the UMAC ® R measuring solution, SWM has not only enhanced its production ef ciency, but also reinforced its dedication to quality and sustainability as well as cus- tomer satisfaction across the diverse industries it serves. The results were nothing short of remarkable. In a world where precision and ef ciency are key, SWM International’s strategic adoption of Zumbach’s UMAC ® R stands as a testament to the power of innova- tion in achieving operational excellence. ZUMBACH Electronic AG P.O. Box CH-2552 Orpund, Switzerland www.zumbach.com “We studied machine time, manpower costs and scrap costs, and the return on our investment was about 3 to 4 months. The solution provided by Jorge Lage at Zumbach reduced our previous process for acquiring an accurate measurement from about 2 hours down to 5 minutes,” Todd Clarke, Production Manager at SWM International. Zumbach UMAC ® R Wall Thickness Visualisation SWM International’s large diameter piping extrusion Vacuum Tank at SWM International’s Richland, PA production facility