PROCESSING | MACHINERY
technical extensions such as discharge extruders, discharge pumps, screen changers, and pelletising systems. One of its latest innovations is SenseHub, a digital platform which turns machine data into a
practical tool for data-driven decisions. effective, the company says, “the flights on the
Above: The modular concept of BUSS
compounding systems allows optimum matching of the individual process parameters
screw are interrupted and interact with three rows of stationary kneading pins located in the barrel wall. The interaction between the moving flights and the stationary pins provide dispersive and distributive mixing simultaneously.” A patent for the original co-kneader was filed for Swiss company Buss by Heinz List on 20 August 1945, and was eventually granted five years later, meaning the patent filing just had its 80th anniver- sary. This is testament not just to its longevity, but also its continued relevance. The original patent was based on a unique compounding principle which involved an axially reciprocating and rotating screw with stationary pins in the kneading barrel. During this process, the material is not only sheared between the pins and kneading flights, but also inverted. This is in contrast to traditional single or twin screw extruders. The central element in the kneader housing is a temperature-controlled, oscillating screw shaft which mixes and kneads the raw materials while a two-piece, hinged housing allows easy access to the process sections ensuring fast cleaning and easy recipe changes. The modular design also allows flexible adaptation to different production requirements. One of the co-kneader’s key advantages is the
separation of compounding, pressure build-up, and pelletising. A practical example is the produc- tion of wood-fibre filled HDPE with a wood fibre content of around 55%. A particular challenge with this material combination was the optimisation of feeding and degassing using a flexible kneader in different configurations. Extensive testing com- pared different degassing methods to determine the exact point and amount of wood fibre to be fed at low temperatures and under low pressure to avoid damaging the wood fibre. The original co-kneading technology is still
considered a foundational development in compounding, and Buss has continued to adapt to meet evolving requirements. In addition to the kneader itself, the company offers the necessary flexibility for customer-specific applications and different process requirements with downstream
54 COMPOUNDING WORLD | October 2025
The platform analyses sensor data such as vibra- tion, oil quality, or torque in real time and provides status assessments via a health score. Deviations are recorded and displayed allowing preventive measures to be taken at an early stage which reduces maintenance costs and cuts downtime.
New advances In September, Farrel Pomini revealed that its Compact Processor, a Farrel Continuous Mixer (FCM) combined with a single-screw extruder on a unitised frame, facilitates more efficient production of outdoor decking using wood-plastic composites (WPC) as it eliminates the need for pelletising before compounding. Central to this capability is Farrel’s grooved extruder equipped with vacuum venting which ensures efficient conveying and stable pressure for consistent, high-quality board extrusion, while effectively removing residual moisture. Making a WPC can be challenging because wood flour is a fluffy powder with a relatively high moisture level of about 5% to 6%. Using recycled polymers adds another element of complexity as it is difficult to feed and achieve a homogeneous mixture. Traditionally, wood flour is first pelletised in a milling process that requires large, costly equip- ment with high maintenance costs. The Compact Processor eliminates this step by directly receiving fluffy wood flour, along with recycled material, through its large feed port at high throughput rates. In the mixing chamber, the combination of large free volume and low shear ensures excellent distributive mixing and high output without overheating or scorching the material. A stock cutter at the mixer discharge cuts the extrudate ribbon, facilitating smooth feeding into the down- stream hot-feed single screw extruder. Extrusion line manufacturer Battenfeld-
Cincinnati says it is aiming to meet the unique demands of modern resource management with the new BC 120-40 DVT single-screw extruder. Billed as the first extruder featuring Dual Vent Technology (DVT), it will also be on display at K2025. One of the more obvious innovations is that whereas degassing connections were once located directly next to each other and served to increase the overall degassing capacity at a single area, DVT creates two independ-
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IMAGE: BUSS
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