Coperion is experienced in the design of compounding lines for heavy layer compounds

Production of heavy layer by the split-feed method

Coperion processing lines have proven themselves for the production of highly filled heavy layer compounds over many decades. Heavy layer compounds are used in the automobile industry for damping engine and driving noise. The extruded films are often backed with felt, foam or carpet. They are then formed into the desired shape on presses or by deep drawing and cut.

Due to the gentle raw material handling and the resulting high product quality, the split-speed process with the twin screw extruder ZSK is the most common production method for heavy layer compounds. In this process the backbone polymers/elastomers, small additives and some of the liquids are fed into the first barrel of the Coperion extruder in separate streams and weighed gravimetrically by Coperion K-Tron feeders. Abrasive fillers are added to the plastic compound downstream by a twin screw side feeder.

In addition to the split-feed production method, heavy layer can also be produced by direct extrusion / inline compounding.

Typical set-up for the production of heavy layer compounds

Comprehensive product range

Coperion plastics twin screws

Compounding Machines and Extruders

Due to their gentle product handling and their excellent mixing behavior, Coperion ZSK extruders are the ideal extruders for the production of heavy layer compounds. With our comprehensive engineering know-how we design the extruder and its peripheral equipment exactly to the needs of your heavy layer application.

Feeding Equipment

Coperion K-Tron has the right feeder to accurately deliver almost any material to the extruder. Highly accurate SFT weighing technology ensures that our gravimetric feeders perform to specification.  Higher accuracy means less waste and better end product.  We have a wide range of products in a variety of configurations to choose from.  Our experienced engineers will help you find the optimal solution for your heavy layer process.

Material Handling Equipment

Coperion K-Tron’s material handling equipment is designed to convey the raw materials required for heavy layer plastics.  Our material handling systems can be designed to transfer a range of materials from additive powders to resin pellets. We can design and provide pneumatic conveying systems to deliver your materials to the feeders, increasing process efficiency. Our experienced systems engineering teams can tailor material handling solutions to the specific needs of your process.

Coperion processing plant

Plants and Systems

Coperion is experienced in designing and building complete compounding lines for the production of heavy layer using the split-feed method. We have also successfully implemented numerous systems for heavy layer production by direct extrusion / inline compounding.

Screw elements


Coperion offers a comprehensive range of services. Our spare parts warehouse is one of the largest in the industry with more than 48,000 parts in the database. These include both original Coperion spare parts and parts from other suppliers.


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