TECHNOLOGY | TWIN SCREW EXTRUDERS
Right:
At K2025, Coperion had a display highlighting the twin screws of its ZSK Mc18 extruder series
providing the flexibility to match specific process requirements. With screw speed options of 600, 900, and 1,200 RPM, it is engineered to operate at maximum power output while maintaining process stability and product quality. After KraussMaffei upgraded its ZE 28 BluePow- er twin-screw extruder in 2024, the ZE BluePower 42–80 series followed with a redesign that improved thermal insulation in the housing area to reduce energy consumption and simplified the cleaning process. In addition, the operability of the side feeder was improved and in the feeding zone intake was optimised with new feed housing geometry while redesigned 4D housings offer improved availability. Thomas Unger, Vice President Technol- ogy Extrusion, said: “Especially in compounding applications, the ZE BluePower series convinces our customers with its high energy efficiency and a uniquely broad application spectrum in the market.” The ZE BluePower size 98 and bigger machines
(122, 142, 166, and 186), are characterised by the UltraGlide system, and from size 28 up to 186, the series offers 100% scalability. The unique Da/Di screw ratio of 1.65 provides a broad processing window across all compounding, recycling, foaming, and film applications. All machine sizes can be operated with a torque density of 16 Nm/ cm³. A configurator will be introduced in 2026 to allow customers to modify the visual layout of the process section directly within the control system.
Torque increase Coperion has increased the torque of its ZSK Mv series, characterised by their large free screw volume with a Da/Di of 1.8, to 14 Nm/cm³, helping them achieve a 24% increase in throughput when process- ing products with high volume and high torque requirements while ensuring improved product quality when processing shear-sensitive products. The increase also means the new ZSK Mv14 achieves the desired throughput ranges at significantly lower
Right: Compari- son of Coperion screw elements of the ZSK Mv14 series and the ZSK Mc18 series. The company says the ZSK Mv14 screw elements are characterised by their large free volume
14 COMPOUNDING WORLD | March 2026
speeds or with smaller extruder sizes which reduces investment, energy costs, and space requirements. In addition, the series has been expanded to include a larger machine size. The new ZSK 140 Mv14 has a screw diameter of 140 mm and achieves up to 40% higher throughputs than the ZSK 125. Its recipe flexibility is greatly increased and the range of applications expanded compared to previous models while its deep-cut screw flights result in a very large free screw volume. In combi- nation with the increased torque, higher filling degrees are possible promoting extremely gentle product processing. With the average shear and thermal stress on the melt being extremely low, product quality is improved. In addition, the ZSK Mv14 allows the material to remain in the process section for an extended period. The company says the performance upgrades have been achieved through improvements in various functional areas, such as using high-performance materials for the screw shafts. At K2025, Coperion exhibited the ZSK 58 Mc18 with new screw elements that it has developed especially for processing fillers. This achieves throughputs of up to 2,500 kg/h with low energy consumption and a high degree of automation (see Compounding World November 2025). Sustainability pressure is a major factor reshap-
IMAGE: COPERION
ing extrusion technology. Twin-screw extruders are now being used for both chemical and mechanical reprocessing of post-consumer recycled (PCR) waste, and they are increasingly being tailored for biodegradable polymers and bio-based materials. Chinese company Nanjing Haisi Extrusion Equipment notes that, “In recent months, we have observed a growing interest among small and medium-sized factories in recycling production scrap and offcuts. While single-screw extruders or two-stage single-screw systems are commonly used for basic recycling tasks due to their simplicity
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IMAGE: AMI/ELDRIDGE
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