Inline Wall Thickness Measurement Optimizes Heat Shrink Tubing Production at DSG‑Canusa

How DSG‑Canusa GmbH enhanced inline quality control and reduced manual inspection through Zumbach’s laser and X‑ray measurement solutions

DSG‑Canusa GmbH, part of the global Mattr group, is one of the world’s leading manufacturers of heat‑shrink tubing and related solutions, serving a wide range of industries with a strong focus on the automotive sector. With more than 200 employees and a large, highly automated manufacturing site in Rheinbach, Germany, DSG‑Canusa continuously invests in production technologies that ensure consistent product quality, process efficiency, and long‑term competitiveness.
For over 15 years, DSG‑Canusa has relied on Zumbach Electronic AG as a trusted partner for inline measurement and quality control. What began with laser‑based diameter measurement has evolved into a comprehensive solution for real‑time monitoring of outer diameter, geometry, inner diameter, and wall thickness, providing DSG‑Canusa with deeper process insight 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 provided reliable inline monitoring of external dimensions, there was no solution in place to measure wall thickness inline. As a result, operators were required to take frequent offline samples throughout the working day to verify wall thickness. This approach that 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. Although several competitive systems were tested, Zumbach’s proven technology, combined with the longstanding partnership and highly positive inline test results, ultimately led to the decision to select 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 within the extrusion and expansion production lines for heat‑shrink tubing. The systems provide real‑time measurement of inner diameter and wall thickness, allowing DSG‑Canusa to continuously monitor two layers inline, well within the RAYEX® S capability of measuring up to four layers.
The impact of inline wall thickness measurement has been significant:
• Substantial reduction in manual sample checks, freeing operators for higher‑value tasks
• Faster response times to process deviations
• Lower scrap rates, as out‑of‑spec material is identified early
• More stable and repeatable processes, particularly during startup and product changeovers
By eliminating frequent manual offline measurements, DSG‑Canusa has not only reduced workload and interruptions, but also gained greater confidence in continuous product quality throughout the entire production run.
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, providing an additional stage of final quality control. KW lump and neckdown detectors further support defect detection by identifying local diameter variations that could compromise product performance.
Together, these systems form a comprehensive inline quality assurance concept, covering critical parameters from extrusion through 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 data‑driven, efficient, and future‑ready production. The ability to monitor critical dimensions in real time supports not only current quality requirements but also lays the groundwork for further automation, process optimization, and digitalization initiatives.
The successful integration of RAYEX® S into an existing production environment demonstrates how incremental technological upgrades, backed by a reliable partner relationship, can deliver tangible operational benefits.