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Coperion Technology Update

New Perspectives in Plastics Manufacturing

Coperion presented current technology trends in large-scale plants for the production of plastics on November 15 and 16, 2011. About 150 interested customers followed our invitation to Al-Jubail, Saudi Arabia and received an overview of the latest developments from Coperion in numerous lectures.

The focus on the first day of the seminar was on extrusion. In his introductory lecture Michael Ueberall, Sales Manager Business Unit Extrusion Systems Polyolefins, explained the basic functional principles of the large-scale ZSK extruders. Based on case examples he demonstrated the effects of current developments on the throughput rate in the production of PP, PE and LDPE. Following Mr. Ueberall, other speakers went into the details of the gearbox and the pelletizers of the large-scale extruders. Finally, two other lectures showed possibilities for considerably increasing the performance of existing ZSK systems by modernization and individually configured service measures.

The second day of the seminar was dedicated to the topic of Materials Handling. First the current design of the plants for plastics manufacturing and the latest developments from Coperion were presented to the guests. The advantages the operator can gain when Coperion provides complete plants from the planning right through to the commissioning were explained by Christoph Schumacher, Head of Business Unit Materials Handling Plastics & Chemicals, in his lecture “Coperion – A specialized LSTK Service Provider”. The logistics management in plastics manufacturing and the modernization possibilities of bulk material handling systems successfully rounded out the comprehensive lecture program.

Your contact:
Werner Strauch, Tel.: +966 3 341 0515, e-mail

Coperion Technology Update
Coperion Technology Update

Ensinger has chosen the ZSK Mc18

Compounding of high-performance plastics

Advantages in process technology drove the decision: Ensinger GmbH, Nufringen ordered a twin screw extruder from our new ZSK Mc18 series. The compounder with 45 mm screw diameter is equipped with two ZS-B side feeders and a ZS-EG twin screw side devolatilization unit . Ensinger, specializing in the production of compounds, semi-finished products, profiles and finished parts of high-performance plastics will produce high quality compounds on the ZSK 45 Mc18 which are reinforced, for example, with glass or carbon fibers.

Ensinger benefits from the improved temperature control in the process section. In the ZSK Mc18 series the cooling channels which surround the process section in each barrel run at right angles to the direction of the material flow. This provides not only a high cooling capacity but also a very homogeneous cooling of the process section. Unlike external shell heaters, cartridge heaters generate heat directly inside the process section, i.e. exactly where it is needed. The wear-resistant oval liners are shrink-fitted (hence gapless) into the extruder barrels for optimum thermal transfer, making the heat exchange between the material in the barrel and the respective extruder section faster and more efficient. For the installation of ZS-B side feeders and ZS-EG twin screw side devolatilization units, the ZSK Mc18 series is equipped with combi barrels that are also fitted with cooling channels, thus permitting optimum temperature control.

The ZSK 45 Mc18 for Ensinger is designed to produce a wide range of different compounds and to use the machine very flexibly. This gives Ensinger the certainty of being optimally equipped for future new or changing market requirements.

Your contact:
Matthias Link, Tel.: +49 (0) 711 897-2617, e-mail
NAFTA contact:
Eberhard Dieterich, Tel.: 201 825-6408, e-mail

Advantages of the ZSK Mc18 at a glance*
More than 30 % increase of specific torque
Throughput rate increase of up to 30 %
Greatly improved productivity
Proven high ZSK safety enabled by new designs and developments
Maximum flexibility by wide application range
Improved compound quality by gentle processing with higher filling level
Increased energy efficiency by reduced specific energy input
Reduced compound temperature at much higher throughput rates
* In comparison with the predecessor model ZSK MEGAcompounder PLUS.
Twin screw extruder ZSK Mc18 from Coperion

Composite knives from Coperion

The new generation of pelletizer knives

Our many years of experience in the production and application of pelletizer knives on Coperion pelletizers has brought further optimization of the product: the new composite knife. This knife ideally unites the advantages of the previous monobloc and bimetal pelletizer knives; it combines two proven materials and can be used universally for all PP and PE applications. It was developed especially for Coperion underwater pelletizers and is already used successfully in extensive practical tests.

With the optimized shaft geometry the composite knife ensures the ideal contact pressure onto the die plate during pelletizing for a very good cutting result and the necessary flexibility to counteract breaking of the knife. The whole knife geometry was revised to optimize the interaction of knife and knife wings. This further increases the performance of Coperion pelletizers.

Your contact:
Helmut Hiller, Tel.: +49 (0) 711 897-3239, e-mail
NAFTA contact:
Rich Taylor, Tel.: 201 825-6445, e-mail

Technical data
Available for all Coperion underwater pelletizers of the sizes UG 300 to UG 925
Cutting width: 2.5 mm
Blade material: Materials Nikro 128 and 143
Composite knives from Coperion

Bulk materials heat exchanger BULK-X-CHANGE®

Successful performance for the production of fertilizers

In line with the debottlenecking of its plants, the fertilizer producing company OCI Nitrogen in Geleen, Netherlands counts on the bulk materials heat exchanger BULK-X-CHANGE® from Coperion. With the help of the BULK-X-CHANGE®, OCI, formerly DSM Agro, has streamlined its production process by cooling down calcium ammonium nitrate (CAN) pellets from 105°C to 35°C.
With an overall length of 16 meters and a diameter of less than 2,500 mm, the heat exchanger is efficiently cooling down up to 60 tons of CAN per hour.

Comprehensive tests in Coperion’s technical center and on the customer’s site preceded the decision in favour of the BULK-X-CHANGE®. Currently the heat exchanger is working successfully and reliably. In addition to the defined cooling of the product, OCI is also benefiting from excellent results with regard to reduced dust emission and lower energy consumption.

Your contact:
Guenther Dehm, Tel.: +49 (0) 751 408-230, e-mail
NAFTA contact:
Paul Martin, Tel.: 469 767-5929, e-mail

Technical data
Capacity: 60 t/h CAN
Cooling down from 105°C to < 35°C
Diameter: < 2.500 mm
Total length: approx. 16 meters
Bulk materials heat exchanger BULK-X-CHANGE®
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