Skip to content Metal contamination is one of the most costly threats in plastic production and recycling. A single stainless steel fragment in a granule feed can destroy a melt filter screen, seize an extruder screw, or shut down an injection moulding machine for days. Mesutronic’s precision detection and inspection systems stop contamination before it stops your line.
In plastic recycling and manufacturing, the raw material stream is not always clean. Post-industrial and post-consumer plastics frequently contain metal fragments: a fastener from a dismantled assembly, a blade chip from a shredder, a wire fragment from a bale. Left undetected, these contaminants cause equipment damage, trigger costly downtime, compromise final product quality, and — in food or medical packaging applications — can create serious liability exposure.
• Iron, brass, aluminum, and stainless steel fragments in regrinds and granules
• Metal chips from worn tooling or shredder blades entering the feed stream
• Wire and fastener fragments from post-consumer baled material
• Ferrous and non-ferrous contamination in pneumatic conveying lines
| Application | Challenge | Recommended Solution |
|---|---|---|
| Plastic Film Recycling | Metal contamination can damage shredders, extruders and melt filters | Mesutronic Metal Detection Systems |
| Injection Moulding | Metal particles can damage screws, barrels and hot runners | Mesutronic Metal Separation Systems |
| Plastic Compounding | Contaminants reduce pellet quality and increase downtime | Mesutronic Inspection Systems |
| Blow Moulding | Material purity is critical for consistent production | Mesutronic Metal Detection Systems |
| Recycled Plastic Processing | Hidden metal contamination can damage downstream equipment | Mesutronic Detection & Separation Solutions |
Mesutronic GmbH, headquartered in Kirchberg im Wald, Germany, has been developing and manufacturing high-precision metal detectors, metal separators, and X-ray inspection systems for over three decades. They supply industries worldwide — with plastics representing 23% of their installed base — and are recognized as a technology leader through sustained R&D investment.
DETECTION AND INSPECTION SYSTEM RANGE
Ideal for protecting equipment that processes plastic granules, regrind, and pellets in vertical feed streams.
These systems detect and automatically eject contaminated material before it enters downstream machinery:
Entry-level free-fall detector. Simple 2-button operation. Designed for granule inspection up to 10mm. Compact, cost-effective protection for smaller operations.
Mid-range free-fall system with optional FDA/EU-certified PE or Teflon sensing tube for direct product contact. High-temperature version available. Robust for demanding environments.
High-hygiene free-fall detector with FDA/EU-certified surfaces. Tool-free disassembly of rejection system for cleaning. Very high sensitivities.
Versatile free-fall system with very high sensitivity. Suitable for pneumatic conveying as well as standard free-fall. Can be mounted horizontally or vertically. Minimal installation footprint.
Optimised for vertical packaging machine integration. High sensitivities (0.4–1.0 mm in steel depending on aperture diameter). Compact for tight installation spaces.
Free-fall detector compatible with pneumatic conveying. Horizontal or vertical mounting. Compact design suitable for constrained installation environments.
For plastic granules transported through lean-phase pneumatic conveying lines under pressure or vacuum (±0.5 bar). Unlike detectors that only alarm, P-TRON systems include an active separation diverter — detected metal is physically rejected from the stream automatically. Maximum granule size: 8mm.
Note: P-TRON systems are designed exclusively for lean-phase conveying lines.
Metal separator with separation diverter for integration into intermittent suction conveyor lines. Entry-level pneumatic line protection with active, automatic rejection of detected metal.
Metal separator with separation diverter for continuous pneumatic conveyor lines. Mid-range system for standard lean-phase transport of plastic granules and pellets.
High-end metal separator with separation diverter for pneumatic conveyor integration. Maximum sensitivity and rejection performance for demanding applications or high-value material streams.
For pipeline conveying systems where detection and alarm is required, and rejection is handled separately or downstream. Both units feature round openings sized to the pipeline diameter.
High-end pipeline metal detector with round opening and maximum interference shielding. For environments with significant electromagnetic interference from nearby motors or equipment.
Simple, cost-effective metal detector with round opening for standard pipeline assembly. Reliable detection for straightforward pneumatic line installations
For protecting recycling lines, washing lines, and sorting conveyors — where bulk plastic material moves horizontally on a belt. Multiple configurations for different aperture sizes and sensitivity requirements. Plastic-optimised detection frequency: 65.6 kHz. Provide your belt width and material height when ordering.
Divisible tunnel detector for assembly in conveyor belts or vibratory channels. Handles larger bulk heights. Optimised frequency for plastic inspection (65.6 kHz). Alutron version available for household recycling streams with aluminium contamination (Tetra-Paks, foils).
Closed tunnel variant of the METRON 05 D. Continuous tunnel for belt-integrated applications. Same plastic-optimised frequency. Aperture sized to belt width + 100 mm clearance.
Mid-range tunnel detector with integrated evaluation electronics. Self-contained unit for straight integration into conveyor belts. No external controller cabinet required.
High-end tunnel detector with integrated evaluation electronics. Maximum sensitivity for demanding recycling applications. Suitable for belt conveyor integration where highest detection performance is required.
Single plate detector for assembly under conveyor belts or vibratory channels for bulk heights up to 250 mm. Available in widths from 200 to 950 mm in 50 mm increments — e.g. METRON 05 S 400 = 400 mm sensitive width.
Simple plate detector for examining plastic parts before beside-the-machine granulators. Detects metal in moulded or extruded parts before they enter size reduction — protecting granulator blades from hard contamination.
The PLASTRON 05 K mounts directly on the material column (hopper throat) of injection moulding machines and extruders. It intercepts contamination at the point of entry into the machine — the last line of defence before the screw and barrel.
Material requirements: non-conductive (no carbon-black additives), non-abrasive (standard version), non-sticky, max temperature 120 degrees C, max installation load 500 kg.
Metal separator for direct installation on injection moulding machines and extruders. Mounts at the material column — protecting screw, barrel, and hot runner from hard contamination entering with the granule feed.
***Particularly relevant for Tederic injection moulding machine operators seeking to protect their equipment investment. Ask Leap Green about combined Tederic + PLASTRON 05 K protection packages.
TRANSTRON L: Complete conveyor system with textile belt for products up to 60 kg. Integrates detection directly into a purpose-built conveyor unit.
TRANSTRON GF: Conveyor system specifically designed for the infeed of crushing and shredding systems. Delivers material to granulators and shredders with integrated metal detection — protecting cutting tools from hard contamination before blade damage occurs.
For plastic film production, stretch film, agricultural film, and non-woven fabric manufacturing. Flat bar detectors scan the full material width as film passes beneath. Maximum material height: 10 mm.
One-piece single-bar plate detector for scanning non-woven fabrics and films. Spans the full production width in a single unit. Straightforward installation for standard film line widths.
Segmented plate detector for non-woven fabrics and films. Available in 300 mm or 150 mm segments for precise contamination localisation across the full width. High-temperature version available
When metal detection alone is not sufficient — for high-value applications, food-contact recycled plastics, or regulatory compliance requirements — X-ray inspection provides an additional layer of assurance, detecting contaminants that electromagnetic detection may miss.
X-ray inspection is particularly relevant for: recycled plastics entering food or medical packaging applications; quality assurance for certified recycled content (PCR/PIR); and compliance with international food safety and material purity standards.
Contact Leap Green to discuss whether metal detection, X-ray inspection, or a combined system is right for your process.
Mesutronic’s digital ecosystem connects your detection systems to your production management infrastructure:
Reduce Manual Compliance Work — Automated testing and data logging dramatically reduces the compliance burden for quality managers — improving the completeness and accuracy of quality records.
Why Detection Pays
Protect Equipment Uptime
Automatic detection and rejection prevents metal fragments from reaching melt filters, extruder screws, injection units, and cutting systems. Reduce unplanned downtime and emergency repair costs.
Maintain Product Quality
Metal contamination in final plastic parts creates reject rates, customer returns, and warranty claims. Detection upstream eliminates the root cause rather than sorting the problem out downstream.
Defend Your Reputation
Product recalls caused by foreign body contamination damage customer relationships and retailer contracts. Prevention through detection is a fraction of the cost of recovery.
Retrofit Without Disruption
Mesutronic systems are engineered for minimal-interference integration into existing production lines. Tailor-made solutions fit around your current conveyor and processing infrastructure.
Audit-Ready Documentation
Digital tools like autoTEST and mesuEXPORT provide automated test records and detection event logs — essential for ISO, HACCP, and food-contact certification processes.
Scalable From One Line to Many
From a single free-fall detector on a granule feed to a multi-line network monitored through mesuLINK — Mesutronic scales with your operation.
INDUSTRIES SERVED
Metal detection and X-ray inspection is relevant across the full range of Canadian plastic manufacturing and recycling applications:
Why Mesutronic. Why Leap Green
30+ Years of Proven Technology
Mesutronic has refined metal detection and inspection technology since the early 1990s. Every METRON and Quicktron system is the product of sustained engineering
Engineered for Plastics
Plastic inspection requires specific detection frequencies and configurations distinct from food or textile applications. Mesutronic’s plastic-optimised systems operate at 65.6 kHz and include the Alutron frequency variant for aluminium-contaminated streams.
Modular & Retrofit-Ready
No production line needs to stop to gain protection. Mesutronic designs systems for integration into existing conveyor, pneumatic, and processing infrastructure with minimal disruption and custom aperture sizing.
Digital-First Operations
mesuREMOTE, autoTEST, mesuEXPORT, and mesuLINK bring Industry 4.0 connectivity to contamination detection. Automated testing, remote diagnostics, and centralised monitoring replace manual procedures.
Leap Green: Your Canadian Representative As Mesutronic’s authorized Canadian representative, Leap Green provides technical pre-sales consultation, system selection support, and integration guidance tailored to your specific process and regulatory environment. |
Part of a Circular Protection System
Detection is one component of a complete circular processing line. As a multi-partner circular enabler, Leap Green Polymers helps you combine Mesutronic detection with FIMIC melt filtration, WEIMA size reduction, and TECNOFER washing — an integrated, protected recycling system.
Most plastic processors don’t know they have a contamination problem until they lose a screen, seize a screw, or face a customer complaint. Detection is the upstream answer — and it’s far less expensive than the alternative.
Talk to Leap Green Polymers to assess your line and identify the right Mesutronic system for your application.
Ensure contaminant-free plastic processing by removing impurities and maintaining consistent material quality during production.
Integrated recycling systems designed for processing PCR (Post-Consumer Recyclate) and PIR (Post-Industrial Recyclate) materials efficiently.
High-performance systems that clean and dry recycled plastics to maintain high material quality and preparation for further processing.
Precision size-reduction machinery that cuts and shreds plastic materials for easier handling and efficient recycling workflows.
Special for size reducing to compact and prepare plastic materials for extrusion and further processing, improving handling and production efficiency.
Including loaders, dosing units, drying and crystallization systems, mixers, storage containers, granulators, dedusting units, mold temperature controllers, and conveying solutions
Advanced detection systems that protect machinery and production lines from metal contamination and foreign materials.
Energy-efficient injection molding systems designed for high-precision plastic manufacturing and reduced operational costs.
Advanced extrusion blow-molding technology enabling eco-conscious production with improved energy efficiency and performance.
Optimized by Seraphinite Accelerator
