PRO­FILE­MAS­TER® PMM Pro­file Di­men­sion Meas­ur­ing Sys­tem

Why PRO­FILE­MAS­TER® PMM?

The Zumbach PROFILEMASTER® PMM is a non-contact inline profile measurement system using 2D laser triangulation to capture accurate cross-sectional geometry in real time for extrusion and cold rolling applications. Unlike shadow-based systems, it delivers true, distortion-free profile data, enabling precise measurement of widths, heights, angles, radii, gaps, and more, reducing scrap, improving start-up efficiency, and supporting full quality control across plastic, rubber, and metal profiles.
Unlike conventional profile measurement systems, PROFILEMASTER® PMM can measure multiple products simultaneously – up to 4 strands at the same time, even when each strand uses a different product recipe. This unique capability reduces equipment requirements, lowers investment costs and delivers individual quality data for every strand in the production process.
The integrated software lets users monitor all key dimensions, with direct DXF file import for profile shapes. Three models in the range cover product sizes from 2 mm to 144 mm in diameter.

• True profile measurement with laser triangulation – the actual cross-sectional shape is captured and displayed in real time, not just shadow projections. Geometry errors appear exactly as they are, enabling faster corrective action at the mill or extruder.
• Measures virtually any profile form – widths, heights, diagonals, thicknesses, angles, radii, depths, gaps, and diameters in a single pass. Profile geometries can be imported directly from DXF files for fast product configuration setup.
• Position and rotation independent measurement – the unique PROFILEMASTER® concept delivers precise, reliable results regardless of how the profile is positioned or twisted in the measuring field. No re-alignment is needed during production.
• Modular system for 2–144 mm profiles: models for small metal and large plastic or rubber profiles, all with SPC, database, and remote access.
• Multi-Strand Measurement: Measure up to four products simultaneously with independent quality control, reporting and recipe management for every strand.

Proven per­form­ance world­wide

PROFILEMASTER® PMM systems are used worldwide in extrusion and cold rolling lines for non-contact, real-time measurement of plastic, rubber, metal, and cold steel profiles across diverse industries. Trusted by both specialist producers and large-scale manufacturers, they improve start-up performance, dimensional accuracy, Cpk, and material yield. With measuring rates up to 150 cross-sections per second and support for unlimited line speed, PROFILEMASTER® PMM ensures precise inline quality control while delivering complete production data for ISO traceability and process optimization.

Fre­quently asked ques­tions

What is the difference between PROFILEMASTER® PMM and shadow-based diameter gauges?
Shadow-based (laser scan) gauges measure the projected width of a product from one or two directions. PROFILEMASTER® PMM uses laser triangulation to capture the actual 3D surface contour from multiple angles simultaneously, reconstructing the true full cross-sectional profile. This means geometry errors – asymmetry, wrong angles, incorrect radii – are shown exactly as they are, not as a single diameter value that masks the real shape.

Can PROFILEMASTER® PMM measure any profile shape?
Yes. The software toolbox allows any relevant dimension to be defined and monitored – widths, heights, thicknesses, diagonals, angles, radii, depths, gaps, and diameters. Profile nominal geometries can be imported directly from DXF files. For most standard profiles, virtually any shape can be measured, so long as it fits within the measuring field. One natural limitation of the laser triangulation principle is that undercuts (areas where the laser beam and camera cannot reach the surface directly, as can occur in complex window profiles or deeply recessed grooves) cannot be captured. In such cases, Zumbach will advise on the optimal number and positioning of camera/laser modules to maximize contour coverage for your specific profile.

Which PROFILEMASTER® PMM model do I need for my application?
PMM 30/50/80 are for smaller profiles (2–73 mm) and are rated IP 65 – suitable for cold steel, metal, plastic, and rubber in demanding industrial environments. PMM 130-4K and PMM 160-6K cover larger profiles up to 144 mm and are typically used for plastic and rubber extrusion. For high-temperature rolling applications, the PROFILEMASTER® SPS is the right choice.

Does the profile need to be in a fixed position in the measuring field?
No. The PROFILEMASTER® PMM concept is designed to deliver accurate results regardless of the profile’s position or rotational orientation within the measuring field. This is a key advantage over systems that require precise product guidance to give reliable readings.

How quickly can I set up a new product?
Product profiles can be imported directly from DXF files in minutes. Nominal dimensions, tolerances, and alarm thresholds are defined in the software. No manual coordinate entry is required for standard profile shapes.

Can the PROFILEMASTER® PMM measure multiple products at the same time?
Yes. With the optional Multi-Strand software package, the PROFILEMASTER® PMM can measure up to four strands simultaneously within a single measuring system. Each strand is individually monitored with its own cross-sectional display, trend analysis, statistics and reporting. Different product profiles and measurement recipes can also be assigned to each strand, making it ideal for applications such as multi-strand rebar, tube and profile extrusion lines.

What data does PROFILEMASTER® PMM record and how is it stored?
All measurement data can be stored in a database with timestamps, product identification, and configurable storage criteria. Data is displayed as cross-section graphics, strip charts, histograms, and SPC charts. The Windows-based system integrates into customer networks via EtherNet, supporting remote access for off-site monitoring or service.