New SKZ Project: Reliably Detecting Foreign Substances in Plastic Melts

The plastics industry faces growing challenges due to rising quality requirements, higher recycling rates, and the need for stable and efficient production processes. The increasing use of recycled materials raises the risk of foreign substances entering the plastic melt. These can significantly impair product quality and cause machine damage at the same time. The consequences include production downtime, unplanned stoppages, and increased scrap.

Transferring foreign material detection from the laboratory to industrial applications
Currently, the industry has few practical methods available for reliably detecting foreign objects early on during processing. As part of the SKZ’s pioneering project, measurement techniques are being evaluated and further developed to detect foreign matter in the melt at an early stage, thereby serving as a tool for process monitoring. The targeted solutions are intended to help sustainably increase process reliability and ensure consistently high product quality. The initial focus is on extrusion, although future applicability to injection molding is conceivable.

“Participation in the project offers companies the opportunity to evaluate innovative testing technology in a real production environment and tailor it specifically to their processes,” says Luis Wachter, Group Leader of Non-Destructive Testing at SKZ. “The collaboration of several companies allows for the sharing of development costs and the development of practical solutions that meet the real-world requirements of the industry.”

Comprehensive Requirements Analysis
A comprehensive requirements analysis is conducted at the start of the project. In this process, the specific needs and expectations of all project partners are systematically documented, and suitable testing systems are selected as a result. In subsequent test series, practical trials are conducted using the materials of the participating partners. The process concludes with the evaluation of the results, based on which confidential recommendations for action are derived and provided for the individual application of the findings in the respective production environment.

“Individual test series are conducted for each project partner so that specific materials, foreign objects, processes, and requirements can be taken into account,” says Wachter.

About SKZ Pioneer Projects
SKZ Pioneer Projects are jointly funded by several companies. The results are made available exclusively to the participating companies and are not published. The goal is to develop practical solutions that can be applied on an individual basis.

Interested companies are welcome to contact Luis Wachter for further information on the process and details. The project is scheduled to start in the third or fourth quarter of 2026 and will run for a total of twelve months.

Further information on the project