Plasticizing units should be able to process a wide range of plastic materials and additives with high output rates. As a consequence, it is essential to design and manufacture screws, which are individually adapted to the respective materials. In addition, the melt quality is one of the main factors to guarantee high quality products in injection moulding and extrusion processes. In order to predict the optimized geometry and process parameters influencing the melt quality of the respective application, we developed a simulation program, with a focus on standard three-section screws. A clear separation of the melt and solid fraction in the screw channel is a precondition, referring to physical models, which are included. For this reason, the main constituent of the simulation program is the calculation of the melting process in an injection moulding plasticizing unit. First of all, a 2D grid generator is used to represent an unwrapped screw channel of a standard three-section screw. Under consideration of the axial screw movement, mechanical, mathematical and physical models based on Tadmor, White and Potente, it is possible to determine the melting process of the individual functional areas. Validation of simulation and experiment data is indispensable to get significant results. In order to verify the measurement relating to the melting profile, so called pull-out tests are normally executed. This method is very time-consuming and very inefficient. With this in mind, we compared two different methods for the in-situ measurement of the solid-bed ratio: Analysing pressure data and ultrasound reflection signals [1] at different axial positions. These methods are more useful to investigate the melting behaviour over the screw channel. [1] Aigner M. 2014. Computational and Experimental Modelling of Transport Phenomena in Single Screw Plasticating Units under Consideration of the Melt Quality.[Dissertation].pp.76-90.