Measuring instruments
SWM International saves $40,000 in one year with Zumbach's UMAC® R
Ultrasonic wall thickness measurement helps improve efficiency, reduce scrap, and accelerate production
Reducing scrap, shortening start-up times, and improving product quality are key priorities for tube and pipe manufacturers—and this is precisely where Zumbach Electronic delivers value with its advanced inline measurement solutions. The company’s UMAC® R ultrasonic measuring system is designed to optimize production processes by providing real-time, high-precision data directly on the line.
A recent application at SWM International, a US-based producer of polypropylene and HDPE tubes and pipes, highlights the impact of Zumbach’s technology in a real production environment. By replacing traditional off-line measurements performed with calipers, the UMAC® R enabled a shift toward faster, more efficient and data-driven quality control, eliminating lengthy measurement procedures that previously required up to two hours and contributed to downtime and material waste.
According to Todd Clarke, Production Manager at SWM International, the impact of the new solution was immediate.
"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."
Faster measurements, less waste
The UMAC® R provides real-time measurement of wall thickness, eccentricity and concentricity, allowing operators to make immediate process adjustments during production. The system significantly reduces start-up times and enables faster product changeovers while maintaining consistent product quality.
Designed for tube and pipe diameters ranging from 0.2 mm to 400 mm, the UMAC® platform combines high-precision ultrasonic measurement with flexible installation options. The ring-shaped measuring head is designed for integration into existing vacuum tanks, making it suitable for both new and existing extrusion lines. Depending on production requirements, the system is available with fixed transducer holders featuring 4, 6 or 8 measuring points.
The integrated UMAC® CI System-on-a-Chip further simplifies operation through recipe-based product management, eliminating manual echo signal adjustments while offering a 1 kHz sampling rate and an integrated web server for enhanced connectivity.
A rapid return on investment
The operational benefits quickly translated into financial results. During its first year of operation, the UMAC® R generated approximately $40,000 in scrap cost savings, while delivering a return on investment in just three to four months.
Beyond the measurable cost reductions, the implementation has helped SWM International improve manufacturing efficiency, reduce material consumption and reinforce its commitment to product quality and sustainability.
The project highlights how advanced inline measurement systems can support extrusion manufacturers in achieving greater process stability, higher productivity and lower production costs—key factors for remaining competitive in today's tube and pipe industry.
For more information or to require a customized quotation, we invite you to contact Zumbach through the references on this page.
