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ZSK Mv PLUS twin screw extruder in new hygienic design

Improved product and production safety

ZSK 54 MEGAvolume PLUS in hygienic design
ZSK 54 MEGAvolume PLUS in hygienic design

Due to the steadily growing hygienic requirements of food producers for food safety Coperion has further developed its twin screw extruder series ZSK Mv PLUS and has introduced a complete new, innovative machine design to the market.

The new ZSK Mv PLUS is equipped with an open base frame out of stainless steel. This design ensures the latest hygienic standards and provides clear advantages to operators. Cleaning efforts drop tremendously and downtime for cleaning is reduced to a minimum due to optimal accessibility of the equipment. In the same time product and production safety have been improved. Coperion uses materials of construction which guarantee the fulfillment of all EU and worldwide guidelines.

Operators also benefit from the ZSK’s new control system CSpro which is based on the latest Siemens SPS S7-1500 hardware and software. Due to its OPC UA interface as well as its web interface it guarantees maximum connectivity to all relevant data of the plant. Therefore it fulfills the industry 4.0 standards.

Coperion’s twin screw extruder ZSK is the result of over 100 years of experiences in extrusion processes and more than 50 years of expertise in food extrusion applications. It excels by its maximum operational reliability and is world reknown for the high durability of all parts. Food production companies using the ZSK Mv PLUS are ranging from cereal manufacturers to high moisture meat analogues producers worldwide.

The performance characteristics of the twin screw extruder ZSK Mv PLUS are basing on a Do/Di of 1.8 (outer to inner screw diameter).Specific torque limits at 11.3 Nm/cm3 and max. screw speed is 1,800 rpm.

Your contact:
Stefan Gebhardt, Phone: +49 (0)711 897 3048, e-Mail

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Experience report of Töpfer – June edition of the magazine "molkerei industrie"

Only sanitary components are used in Töpfer's production

Baby food of Töpfer
Use of Coperion hygienic components in Töpfers' baby food production

As producer of nutrition and body care products for infants, Töpfer GmbH in Dietmannsried, Germany is obliged to extraordinary accuracy in production and packaging. The company, which, from a technological point of view, classifies itself somewhere between a dairy and pharmaceutical producer, pays highest attention to the selection of sanitary components for its process. As a result, Töpfer has been a dedicated customer of Coperion for the supply of sanitary rotary valves and diverter valves for powder conveying.

“Through a former employer, I have already been in close contact with company Waeschle, who already was leading in powder conveying technology in the materials handling industry. Therefore, it made sense, that 10 years ago we contacted their successor Coperion, to further improve our sanitary standard”, explains head of production Alfred Weixler.
At that time Töpfer bought their first sanitary rotary valve. Meanwhile five rotary valves and four diverter valves are in use in the production site at Dietmannsried.
In addition, Thomas Bürkel, Managing Director and responsible for production explains that Töpfer is in the project phase for modernization.
Also here, Coperion components will be installed at key areas, says Bürkel.

Coperion Diverter Valve WYK
Coperion Diverter Valve WYK
Coperion Rotary Valve ZRD
Coperion Rotary Valve ZRD

EHEDG-certified
Daniela Oehler, product manager at Coperion and active member in the EHEDG working team dry solids explains: “Our components are not only designed according to EHEDG guidelines, they are also EHEDG certified. This differentiates enormously between competitor products, who only adapted their design to stainless steel.
What distinguishes Coperion components, is the gap free design, especially in critical areas, such as inlet flanges or side cover gaskets. This is very important, when the production plants are cleaned wet, in order to prevent product deposits and also humidity residues in gaps.
Andreas Sick, Head of Töpfer's Maintenance explains: “ We regularly clean dry and also wet from time to time. After each cleaning process we open the rotary valves to check if there are water residues. Until today, we never found anything. In this context, Weixler highlights the user friendliness of Coperion’s flame proof rotary valves, who can be disassembled with little effort.
Per Andreas Sick: “The rotary valves run perfectly. We haven’t been able to find a better product in the market.”

Both Töpfer employees are also satisfied with the Coperion after sales service. Weixler: “They do not only sell, but also take care of their customer afterwards”.

Jochen Sprung, Head of Sales and Business Development at Coperion summarizes this perfectly: “It is our utmost interest to keep in close contact with the users. This gives us the necessary impulses to further develop our products.

Published in the June edition of the magazine "molkerei industrie"

>> More information on our high-tech components for the food industry

Your contact:
Jochen Sprung , Tel.: +49 (0)751 408 584, e-Mail

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Reliable and cost-efficient solution for feeding systems

Coperion K-Tron introduces unique new Electronic Pressure Compensation for its high-accuracy loss-in-weight feeders

EPC electronic pressure compensation
Basic principle of EPC electronic pressure compensation applied in gravimetric feeding system in a schematic presentation

Coperion K-Tron has introduced a unique new Electronic Pressure Compensation (EPC) system for their high-accuracy loss-in-weight feeders. The main advantages of the new system include improved accuracy and reliability as well as lower initial cost and easier installation compared to traditional mechanical pressure compensation systems. Retrofitting options for existing feeders are available. EPC can be installed on a majority of Coperion K-Tron gravimetric feeders in almost any application and all industries.

In a closed feeding system, pressure build-up inside a feeder can significantly impair weighing accuracy. The commonly installed mechanical pressure compensation systems are sensitive to structural factors and machine alignment and may therefore be intricate or even unreliable. Coperion K-Tron has now developed a clever but simple electronic solution for accurate and steady pressure compensation in feeder hoppers. The modular design incorporates pressure sensors and electronics tailored to interact smoothly with Coperion K-Tron’s KCM feeder control system. Depending on set-up and requirements, sensors can be positioned on the feeder hopper and, if required, on the material discharge tube. The software implements a self-optimizing compensation algorithm for best performance and dynamics identical to those of Coperion K-Tron’s SFT load cells, which allows for highly accurate feeding results, even in systems with perceivable pressure fluctuations, both positive and negative. A separate field evaluation kit allows for the assessment of potential pressure issues in existing installations.

Your contact:
Sharon Nowak, Tel.: +1 856 256 3119, e-Mail

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Loss-in-Weight Feeder: How to create your perfect product

Key Factors and Solutions for Improving Feeder Accuracy

Loss-in-Weight Feeder
Loss-in-Weight Feeder of Coperion K-Tron

Loss-in-weight feeders are gravimetric feeders that directly measures the material’s weight to achieve and maintain a predetermined feed rate.

The feed rate is measured in units of weight per time (e.g. kg/h). This setpoint is programmed by the operator in the feeder control. A constant discharge of bulk material from the hopper is maintained by continuously weighing the hopper including the contained bulk material and regulating the speed of the feeding device accordingly. Accurate regulation is therefore accomplished by comparing the rate of the actual weight loss to the desired setpoint. This enables the control system to compensate for non-uniform material flow characteristics and variations in bulk density, therefore providing a very high degree of feeding accuracy.

Coperion K-Tron offers the optimal LIW feeder system, which integrates a high resolution and fast response weighing system and also accounts for a number of additional influences on feeder performance:

1. Optimizing Screw Fill and Material Flow in Feeder Hoppers

ActiFlow
ActiFlow - self-optimizing flow aid for loss-in-weight feeders

When using single screw feeders for feeding cohesive materials, the material is often flung off the screw flights. This material then accumulates inside the outlet tube, causing buildup and, eventually, fluctuations in the consistent output of the screw feeder. In these cases, a co-rotating twin screw design will be the better choice. Twin screws are often used for more cohesive powders due to the "self-wiping" effect of one screw against the other, which not only helps to transport the material, it also minimizes or even eliminates material buildup.

In addition, there are different options available for the type of screw configuration. For example, if the cohesiveness of a powder increases due to a higher content of moisture or fat, a twin screw with a finer pitch might create a type of extrusion or squeezing effect that releases the moisture and causes additional material buildup issues. In this case, an auger type screw configuration with a larger tolerance on screw flights might be better suited.

Flow-aid devices that may be required in or on the feeder’s hopper will assure that the process material flows into the feeding device as uniformly as possible.

A range of flow-aid devices include:
- Mechanical hopper agitators that stir the material and break down any bridging or rat-holing of the material.
- Integrated vibration technologies, such as the innovative Coperion K-Tron ActiFlow device, which operates by applying vibration to the hopper wall using an external drive at a variable frequency and amplitude.

2. Weight Balancing and Isolation from Vibration Influences

Filter algorithm
Filter algorithm of Coperion K-Tron

Because weighing is the basis for feeding accuracy, the feeder as well as the weighing unit must be isolated from the influences of external forces, friction, vibrations or shock. This is accomplished by installing flexible connections e.g. at the feeder inlet and outlet. The feeder must have a stable mounting on shock mounts, and strong air currents near the feeder must be eliminated. Modern load cells and control algorithms, such as those supplied by Coperion K-Tron, measure the weight and apply sophisticated digital filtering algorithms to eliminate typical plant vibrations from the weighing data.

3. Pressure Compensation

If the LIW feeder is discharging material into a variable pressure environment such as a pressurized or vacuum conveying line, a pressure or vacuum pulse can cause a feed rate error. This pressure pulse affects the hopper’s instantaneous weight measurement by exerting an upward force on the hopper outlet, in effect slightly lifting the hopper so that its weight reads less. The controller interprets this as too much material delivered and slows the screw feeder down thus the actual feed rate is less than desired. Conversely, a consistent positive pressure inside the hopper can also restrict the weight loss sensed, thus the control interprets this as not enough material being fed and speeds up the screw feeder, resulting in too much actual material being fed.
As explained above, Coperion K-Tron’s innovative Electronic Pressure Compensation (EPC)can be used to automatically detect changes in pressure within a feeder and adjust the weight signal accordingly. This allows the feeder control to compensate for pressure changes in the process and accurately regulate the feed rate.

Summary

Proper installation, the ideal weighing configurations, and the proper choice of feeder controls and instrumentation can ward off a variety of future process problems. Understanding the significance of these influences is critical for achieving optimal system performance. The optimization strategies outlined above all will result in higher performance standards for LIW feeding. By understanding the returns on investment of a higher accuracy feeding technology, and ensuring the optimization of its performance, an overall increase in process profitability and quality can be achieved.

Your contact:
Sharon Nowak, Tel.: +1 856 256 3119, e-Mail

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Application sheet for download

Solutions for Feeding, Conveying and Extrusion for Confectionary and Chocolate Processes

Confectionery and Chocolate Manufacture

The systems engineers at Coperion and Coperion K-Tron have extensive experience in innovative design systems for chocolate and confectionary manufacturing. The attached application sheet includes a variety of solutions for your completely integrated material handling and feedings sytems (whether batch or continous operation), including hygienic food components and the high efficiency twin screw extruder, supplied by Coperion and Coperion K-Tron.

The application sheet is available as download.

>> Download your solution for feeding, conveying and extrusion

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SAVE-THE-DATE

Coperion and Coperion K-Tron at the IFT 2016

IFT 2016

IFT 2016 - Annual Meeting & Food Expo
Chicago, IL/USA
July 16 - 19, 2016
Booth no. 3918

Visit our booth and see a new extruder, ZSK 18 MEGAlab designed specifically for the food industry!

We look forward to meet you!

5th Food Extrusion Seminar

5th Food Extrusion Seminar

Coperion and German Institute of Food Technologies (DIL) are extremely pleased to be conducting the Food Extrusion this year:
On November 8 and 9, 2016 at Coperion in Stuttgart/Germany.

At this event our experts will provide you with both basic knowledge and the latest technical developments and trends around the theme of food extrusion in theoretical and practical units.

Save this date!

More information will follow shortly!

Your contact:
Uta Kühnen, Phone: +49 (0)711 897 3183, e-Mail

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