Enables Compounding and Extrusion Processes

The ZSE MAXX series from Leistritz Extrusionstechnik is a versatile twin screw extruder designed to tackle complex compounding and extrusion challenges across plastics, pharmaceutical, and food industries. With its unique combination of high specific torque up to 15 Nm/cm³ and a large free volume (OD/ID = 1.66), it ensures effective compounding of materials like polyethylene pellets, polypropylene fibers, and HPMC tablets. The ZSE MAXX excels in continuous, high-speed operations, facilitating seamless integration into existing high-throughput production lines.

Equipped with a modular barrel system and a comprehensive array of screw elements, it allows for precision customizations tailored to specific processes such as direct extrusion, mixing, and granulation. Its state-of-the-art control systems enable real-time monitoring and process adjustments, enhancing production efficiency and product consistency.

Energy efficiency is achieved through optimized motor control and enhanced cooling via a patented splined shaft connection for thermal management. Available in stainless steel options to handle various compounds, the ZSE MAXX also supports GMP compliance for sensitive pharmaceutical applications. With robust engineering support and customization options, it sets the standard for integrated extrusion solutions.

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Processes High Torque and Volume Extrusion Tasks

The ZSE MAXX series from Leistritz is a twin screw extruder designed for high torque and volume applications in the plastics, pharmaceutical, and food industries. Its unique construction combines a large free volume (OD/ID = 1.66) with a patented splined shaft connection, maximizing torque up to 15 Nm/cm³. This extruder excels in compounding, mixing, and melt extrusion tasks, producing plastic pellets, pharmaceutical tablets, and textured protein products efficiently. It offers a continuous operation mode, integrating seamlessly with upstream and downstream processes.

Engineered for GMP compliance, it is ideal for pharmaceutical applications requiring stringent quality standards. The ZSE MAXX series utilizes optimized liquid coolant flow for enhanced cooling, ensuring consistent extrusion performance without overheating. The system is available with various screw elements and a modular barrel design for customized configurations. Additionally, it supports CIP cleaning systems, minimizing downtime and contamination risk. Operators benefit from its intuitive control interface, which facilitates process monitoring and adjustments.

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Processes Compounds and Granulates Diverse Materials

The ZSE MAXX Series from Leistritz is a robust twin screw extruder system designed for precision in complex processes such as compounding and granulation. With its high specific torque of up to 15 Nm/cm³ and OD/ID ratio of 1.66, it efficiently processes materials across plastics, pharmaceutical, and food industries. The series integrates seamlessly into continuous operations, supported by its enhanced cooling capacity and patented splined shaft connection. Applicable in producing plastic pellets, pharmaceutical tablets, and textured soy proteins, it operates with high-speed and GMP-design for the most demanding industrial standards. Its modular design offers easy cleaning and maintenance, with options for customization to fit unique production needs, ensuring compatibility with a range of materials. Compliance with GMP ensures it meets rigorous standards, making it a reliable choice for manufacturers focused on efficiency and product quality.

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Cooks and Mixes Low Shear Confectionery Recipes

The Extrufood cooking extruder from Extrugroup is a twin-screw, counter-rotating machine crafted for the efficient cooking and mixing of low shear confectionery recipes, including licorice, fruit gums, caramels, and chewy sweets. Its unique design includes a stainless steel base supporting critical components like the gearbox, de-aeration, tempering, and dosing systems, all seamlessly integrated for reduced operational complexity. The extruder employs a two-zone cylinder for cooking and vacuum cooling, using water tempering for precise temperature control. Starting up with electric heating, it capitalizes on internal friction to cut energy usage by up to 70%. With a PLC-based control system, available in Siemens or Allan Bradley configurations, it ensures easy integration into existing lines. Maintenance is streamlined through removable barrels and screws, enhancing uptime and operational efficiency. Suitable for a range of industries including confectionery, pet food, and plastics, it has a proven track record and is backed by over 50 installations providing exceptional results.

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Forms and Colors Confectionery and Plastic Products

The Forming Extruders from Extrugroup are engineered for precision and flexibility in confectionery, pet snacks, and plastic production. Equipped with twin-screw, co-rotating technology, these extruders provide seamless processing of various viscous masses—ranging from licorice and chewy candies to custom-shaped plastic components. Their self-wiping intermeshing screws ensure easy cleaning and reduce downtime, while the optional twin-screw, counter-rotating infeed ensures stable, de-aerated mass flow for consistent product quality.

These extruders can produce a wide array of end-products, including licorice strings, gummy bears, fruit leather strips, and more. The Diemix® functionality allows for mixing color and flavor right after the forming process, offering versatility in product design. Built on a single stainless steel frame, they deliver robust performance and corrosion resistance, suited for continuous, high-speed operations. All units can be customized to meet specific production needs, benefiting from Extrugroup’s engineering support and compliance with industry standards, ensuring reliable integration into existing processing lines.

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Processes APIs and Solid Dosage Forms

The ZSK Pharma Twin Screw Extruders from Coperion are engineered to enhance the continuous processing of active pharmaceutical ingredients (APIs) and solid dosage forms. Featuring a modular design, these extruders provide flexibility in processing with adjustable barrel and screw configurations, ensuring precise mixing and controlled temperatures to prevent API degradation. Ideal for producing controlled-release tablets, sustained-release capsules, and transdermal drug delivery patches, they are instrumental in pharmaceutical applications requiring high levels of dispersion and encapsulation. The ZSK Pharma Extruders offer specific torque of up to 18 Nm/cm³, accommodating high throughput while maintaining product integrity. Integrated with PLC control systems that comply with CFR Part 11, they facilitate seamless automation and easy scale-up from R&D to full-scale production. Constructed in GMP-compliant stainless steel with FDA-compliant lubricants, these extruders ensure reliability and safety. The self-cleaning twin screws and compact design allow for quick operation, reduced maintenance, and minimal space requirements, supported by Coperion’s extensive engineering expertise and after-sales service network.

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Streamlines Filtration and Compounding in Recycling

The ZSK FilCo Filtration Compounder by Coperion revolutionizes recycling with a unique system that integrates filtration and compounding into a singular production step. Designed for polymer processors and recyclers, this equipment simplifies the processing of post-consumer recyclate and highly contaminated polymers. Working with the ZSK twin screw extruder, the ZSK FilCo melts, homogenizes, and devolatilizes plastic waste before filtering out contaminants. This processed melt is reintroduced for compounding with various fillers or reinforcing materials, such as glass or carbon fibers.

Applications span across the recycling of diverse plastics, culminating in high-quality products like pelletized plastic recyclate and fiber-reinforced composites. This system notably reduces energy consumption and emissions by over 50% compared to traditional methods, due to its streamlined design that eliminates the need for multiple melting processes. The ZSK FilCo handles solid, granule, and film flake inputs, all while maintaining continuous, high-speed operation. Compact and efficient, it offers consistent quality improvements and reduced thermal stress on polymers, making it a crucial asset for sustainable materials manufacturing.

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Processes Low Bulk Density Materials Efficiently

The ZSK Mv PLUS Twin Screw Extruder from Coperion is engineered to enhance productivity for industries facing the challenge of processing products with low bulk density. This extruder series stands out with its large free screw volume, high screw speeds, and significant specific torque, making it versatile for applications like plastics compounding, chemical processing, and pet food production. By achieving high throughputs at specific energy requirements under 0.13 kWh/kg, it increases plant productivity and formulation flexibility significantly.

Designed for continuous, high-speed operations, the ZSK Mv PLUS handles applications ranging from masterbatches and polyolefins to bioplastics and battery materials. It can support throughput rates up to 40% higher than its predecessors. The extruder’s robust automation and integration capabilities feature user-friendly control systems and electronic maintenance openings for minimized downtime. The equipment also offers various wear protection solutions and corrosion-resistant material options to meet specific process demands.

Moreover, its innovative Feed Enhancement Technology (FET) and side devolatilization systems ensure efficient processing of shear-sensitive and filler-rich materials. Coperion backs this extruder with comprehensive process engineering support and a global service network, offering customized solutions to match your facility’s precise needs. Whether you are in plastics recycling, battery manufacturing, or food processing, the ZSK Mv PLUS delivers reliable, cost-effective, and scalable extrusion solutions.

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Pelletizes and Cuts Extruded Materials

The Centric Pelletizer ZGF Series from Coperion is engineered to enhance pelletizing efficiency for a wide range of industries, including food, pet food, chemicals, and pharmaceuticals. What sets this equipment apart is its precise knife rotor system, which centrally aligns to the die plate, cutting extruded products directly at the end of the extruder. This configuration ensures uniform pellet length and maintains high product quality. Ideal for producing cornflakes, fish pellets, dog kibble, polymer pellets, and pharmaceutical tablets, the series supports continuous, high-speed operations with adjustable pellet length through variable knife speeds. The ZGF Series integrates seamlessly with twin screw extruders, connected via quick release mechanisms for fast assembly and disassembly, minimizing downtime in your production line. Its stainless steel construction provides corrosion resistance, suitable for various operational environments. Moreover, the pelletizer comes equipped with a safety feature to ensure the hood remains closed until the motor stops, enhancing operational safety. Customization options, such as the number of knives and rotor speed, allow you to tailor the machine to specific production needs, supported by Coperion’s engineering expertise.

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Compounds and Pelletizes Plastic and Chemical Materials

The CTE PLUS series from Coperion Nanjing offers a robust twin screw extruder solution designed specifically for the needs of small to medium-sized manufacturers in the plastics and chemical industries. These systems are distinguished by their modular design and the precision engineering of Coperion Stuttgart, ensuring reliable compounding and pelletizing of diverse materials, such as engineering plastics and cable compounds.

Utilizing closely intermeshing, co-rotating twin screws, these extruders efficiently mix, degas, and form materials into a consistent high-quality output, suitable for end-products including polycarbonate sheets, thermoplastic elastomer grips, and low smoke halogen-free cables. Each model, such as the CTE 50 PLUS, balances cost with performance, offering a specific torque of 7.2 Nm/cm³ and throughput rates from 30 kg/h to 5,000 kg/h, depending on the model size.

The CTE PLUS is adaptable, featuring flexible process section configurations and readily integrates into existing production lines with its advanced control systems ranging from simple relay controls to sophisticated PCC systems for real-time line management. Each machine adheres to strict quality standards with a Factory Acceptance Test at Coperion’s Nanjing site, ensuring dependable operation and high process safety supported by new gearboxes designed for longevity and performance. Ideal for compounding processes requiring precise formulation, this series provides significant energy efficiencies and can be tailored with TÜV CE certification for validated operations.

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