Digital Platform C-BEYOND

Welcome to Coperion's next level of digital solutions, which contribute to a significant increase in productivity, plant availability and the OEE (Overall Equipment Effectiveness) value using intelligent diagnostic and monitoring functions.

C-BEYOND determines the OEE value of both, individual ZSK extruders, as well as an entire plant, at any time. Moreover, C-BEYOND provides order planning support. Current production quantity data is available in real time. The production process can be documented in detail using this platform and maintenance work can be scheduled to best advantage. In addition, C-BEYOND calculates both energy consumption and CO₂ emissions per kilogram of plastics produced.

Twin Screw Extruder ZSK 58 Mc¹⁸

An eye catcher at our Booth 14B19 in Hall 14 will be the high performance ZSK Mc¹⁸ extruder with a 58 mm screw diameter. With its high specific torque of 18 Nm/cm³, it is especially suited for efficient compounding of plastics at very high throughput rates and with comparatively low energy consumption.

The extruder will be equipped with a process section, which will allow revealing insights into the intensive mixing behavior of the twin screws. 

The ZSK extruder will be equipped with a Coperion K-Tron T35 Quick Change Feeder (QC) designed for applications requiring quick changeover of materials and convenience of fast cleaning. 

Coperion K-Tron T35 Twin Screw Feeder with ActiFlow™ and EPC

The Coperion K-Tron T35 loss-in-weight twin screw feeder can be used for accurate feeding of free flowing powders and fine granulates but it particularly suited to feeding difficult materials such as pigments, sticky, bridging or flooding powders, fiber and fiberglass. T35 feeders offer feed rates ranging from 1.82 to 2267 dm³/h (0.06 to 80 ft³/h), depending on the type of material.

Coperion K-Tron’s ActiFlow™ Bulk Solid Activator for loss-in-weight feeders is the perfect add-on solution for poorly flowing materials as it reliably prevents the formation of bridges or ratholes.

Electronic Pressure Compensation (EPC) is a smart solution for installations where pressure from up- or downstream systems can affect the reliability of the weighing scale. Sensors automatically detect changes in pressure and compensate the weight signal accordingly.

All Coperion K-Tron feeders are CE compliant.

Twin Screw Extruder STS 35 Mc¹¹ for Masterbatch Production

Coperion offers a twin screw system for the compounding of high-quality masterbatches, which will be shown at Booth 14B19 in Hall 14. This STS 35 Mc¹¹ twin screw extruder ensures outstanding efficiency and cost savings.

The STS Mc¹¹ compounder comes with a screw diameter of 35 mm [1.38 in] and a maximum specific torque of 11.3 Nm/m³. It achieves throughput rates of up to 300 kg/h. The diameter ratio D_o/D_i of 1.55 gives the best shear-to-free volume ratio for proper dispersion of all ingredients. The twin screws feature a closely intermeshing system, resulting in self-cleaning properties of the process section. The overall design of the extruder is compact, dust-free and easy to clean thanks to its smooth surfaces.

AccuRate® Series 602 Volumetric Feeder

For volumetric dry material feeding applications, economical AccuRate Series Feeders handle a wide variety of fine powders, flakes, granules, chips, and pellets. Designed with a unique form of agitation, the Series Feeders feature a Tuf-Flex™ vinyl hopper that is agitated on the exterior by two alternating paddles. The paddle action gently massages the material down into the metering screw, eliminating ratholing and bridging while conditioning material into a consistent bulk density. This results in excellent accuracy due to the even filling of the feed screw.

Feed rates range from 0.0005 to 8,000 dm³/h (0.000017 to 280 ft³/h), depending on the model.

Key Benefits

• Simple, compact design
• Rugged stainless steel housing with easily removable side panels
• 'Massaging' paddle system
• Double shaft seals to prevent powder leakage

MechaTron® Coni-Flex Single Screw Feeder

Discover the MechaTron® Coni-Flex single screw feeder, a new addition to the Coperion portfolio, at our booth 14B19 in Hall 14. It is designed to streamline operation during frequent material changes and multiple cleaning cycles. Its innovative design allows for complete disassembly, eliminating the need to remove upper extension hoppers, bins, bulk bags, or IBCs for cleaning and maintenance. This unique feature leads to significant time and cost savings. Volumetric and gravimetric configurations available.

Feed rates range from 0.006 to 31,150 dm³/h (0.0002 to 1,100 ft³/h), depending on the model.

Key Benefits

• Robust design withstands harsh environments
• Conical hopper optimizes mass flow
• Coni-Flex flexible feed hopper agitated by a paddle system for gentle material handling
• Ease of disassembly reduces maintenance time

ProRate PLUS-MT Twin Screw Feeder

At K 2025 the preconfigured ProRate PLUS feeder line will be represented by the PLUS-MT twin screw feeder at Booth 14B19 in Hall 14. Four models, zero features you don’t need: ProRate PLUS feeders are simple to integrate, to fill, to operate, and to clean. Three single screw feeders are designed for free to moderate flowing bulk materials and a twin screw feeder is available for moderate to free flowing powder additives. All four models are robust and reliable, featuring proven weighing and control technology. The preconfigured ProRate PLUS line addresses the increasing need for durable and economical feeding solutions in the plastics sector that offer a rapid return on investment.

ProRate PLUS feeders can manage feed rates ranging from 3.3 to 4800 dm³/h (0.12 to 400 ft³/h), depending on the model.

Key Benefits

• SIMPLE to install and operate
• ROBUST design
• RELIABLE feeding, weighing and control technology
• Compact design, ideal for clustering around an inlet
• CE compliant

SmartConnex Feeder Control Systems

Coperion K-Tron’s SmartConnex control environment delivers full functional flexibility and the connectivity you need.

Each feeder is supplied with a SmartConnex feeder control module (KCM),  comprising a combination of  control board & motor drive module with optional user interface, mounted directly at the feeder (or remote where required). KCM control modules include a variety of algorithms to ensure optimal feeding performance even in challenging plant environments.

The K-Vision line controller provides comprehensive control capability with maximum flexibility and connectivity for systems up to 24 weigh belt feeders, loss-in-weight feeders, volumetric feeders, batchers, flow meters, Bulk Solids Pump (BSP) feeders or PID controlled devices as well as pneumatic refill systems in one or two lines.

Key Benefits

• SmartConnex puts the 'brain' at the feeder
• Fewer components and less wiring mean lower costs
• Improved short-term accuracy
• Host connectivity at all levels

High Accuracy SFT Weighing Technology

Coperion K-Tron pioneered vibrating wire technology for the process industries and today Smart Force Transducer (SFT) weighing technology continues to represent the leading edge of process weighing technology. Vibrating wire load cells and scales have proven themselves ideal for continuous weigh-feeding applications. SFT weighing systems are flexible, reliable, accurate, linear, and cost effective.

Key Benefits

• 100% digital design, no calibration required
• Advanced single wire weighing technology
• Resolution of 1:8'000'000 in 20 ms
• Digital low-pass filter reduces effect of plant vibration
• Weight captured, linearized and temperature compensated 450 times per second

Competence in Systems Design for Compounding, Polyolefin Manufacturing and Plastics Recycling

With the help of a 3D simulation, we will be demonstrating our comprehensive expertise in system design and engineering for plastics compounding, polyolefin manufacturing and plastics recycling. Visitors to our Booth 14B19 in Hall 14 will gain detailed insights into the operation of single components and entire plants. Informative simulations help to experience interactively Coperion's process solutions competence.

Service Agreements

Leveraging our innovative capabilities and industry expertise, we are committed to being your partner not just during the acquisition of your machinery, but throughout its entire lifecycle.

Our mission is to support you with strategic initiatives that ensure your equipment remains operational for years, minimizing risks while maximizing availability and efficiency.

To achieve this, we have developed a range of maintenance service packages. These Service Agreements offer consistent maintenance for your equipment, ensuring it stays in optimal condition over time. Our proactive service schedule significantly reduces machine downtime and mitigates the likelihood of unforeseen issues.

Condition Monitoring System for ZSK Extruders

Coperion is excited to introduce the ZSK twin screw extruders sizes ZSK 40 to ZSK 133, now equipped with an advanced condition monitoring system. This innovative system will be showcased at Booth 14B19 in Hall 14.

The primary aim of this condition monitoring system is to enhance maintenance planning significantly. It offers a highly dependable yet cost-effective solution that focuses on two critical parameters of extruder condition: drive vibrations and oil quality.

With this reliable condition monitoring system, any irregularities in extruder performance can be identified early, helping to prevent potential damage. This allows for proactive scheduling of service calls, minimizing the extruder's downtime. 

Test Centers Worldwide

Coperion operates global test centers designed for a wide range of applications, including feeding and extrusion, product handling, conveying, and various other processes.

These test centers serve as the perfect environment for comprehensive testing of any challenges faced in a production facility, such as product behavior, new formulations, and throughput rates. Depending on the specific process requirements, the latest innovations from Coperion are incorporated into the test setup, allowing for evaluation before any capital investment is made.

Our test centers can accommodate tests with throughput rates ranging from a few kilograms per hour to medium production scales, enabling optimization of processes. Utilizing established scale-up techniques, our specialists ensure that the findings from these tests are effectively translated to full production scale.