Innovative ZS-B MEGAfeed Side Feeder Makes Plastics Recycling Markedly More Economical

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The ZS-B MEGAfeed side feeder significantly increases fiber and flake feed rate into the ZSK twin screw extruder, making many plastics recycling processes markedly more economical.

Trailblazing New Development for Plastic Fiber and Flake Recycling

With the ZS-B MEGAfeed side feeder from Coperion, the recycling of plastics reaches a new dimension. The ZS-B MEGAfeed makes the recycling of lightweight, very voluminous recycled flakes and fibers significantly more economical and, in some cases, possible in the first place.

Thanks to the innovative design of the ZS-B MEGAfeed side feeder, plastic recyclate with bulk densities starting as low as 20 kg/m³, which was previously considered feed-limited and therefore not economically recyclable, can be reliably fed in large quantities into the ZSK twin screw extruder.

New perspectives in mechanical and chemical recycling

Both in the recycling of post-industrial waste and in the reprocessing of post-consumer waste, the ZS-B MEGAfeed technology opens up completely new dimensions. The ZS-B MEGAfeed achieves an immense increase in the feeding rate of flakes and fibers from a wide variety of plastics (e.g. PA, PE, PET, PP), and thus significantly higher throughput rates - in both mechanical and chemical recycling.

Video: Coperion's ZS-B MEGAfeed Side Feeder

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Using the innovative ZS-B MEGAfeed side feeder, plastic recyclate with bulk densities starting as low as 20 kg/m³, long considered intake-limited and thus not worth recycling, can be reliably fed in large quantities into the ZSK twin screw extruder and be concurrently recycled and compounded.

Advantages of the ZS-B MEGAfeed side feeder

  • Significant increase in the economic efficiency of recycling plastic flakes and fibers
  • Flake and fiber waste, previously considered non-recyclable with a twin screw extruder, now becomes a valuable raw material for plastics recycling and compounding.
  • Fluffy material can be easily handled
  • Preconditioning process steps previously necessary, such as compacting, premelting and prefiltration, are completely eliminated. Melting, compounding, degassing and filtration are now combined in one machine/process step without thermal stress
  • Significantly lower total cost of ownership as higher throughputs are achieved or smaller extruder sizes are sufficient for a given throughput
  • Reduced investment costs and energy consumption, less emissions. The recycling process becomes significantly more efficient with the ZS-B MEGAfeed
Coperion's ZS-B MEGAfeed Side Feeder - Throughput Rates
The significantly improved plastic fiber and flake feed rate using the ZS-B MEGAfeed side feeder leads to enormous throughput increases when recycling plastics with a ZSK twin screw extruder

ZS-B MEGAfeed side feeder for various recycling applications

Coperion Upcycling Solutions

Mechanical Upcycling

Mechanical upcycling of fibers and flakes can now be done with high throughput in one process step. The recyclate no longer has to be melted (agglomerated/compacted) on one line and compounded on another. Thanks to the ZS-B MEGAfeed, the entire process is possible within one ZSK twin screw extruder – at extremely high throughput rates. Investment costs for the process are reduced, production becomes more efficient and energy consumption is significantly lower.

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PET Bottle Flakes

PET Recycling

When recycling PET, the feeding rate is no longer a limiting factor. With the ZS-B MEGAfeed PET flakes and fibers can be fed into the ZSK twin screw extruder in large quantities, and processed there. Existing Coperion PET recycling lines can be retrofitted with the ZS-B MEGAfeed technology.

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Recycling of Post Consumer Waste

Chemical Recycling

Using the ZS-B MEGAfeed post-consumer waste can be fed in very large quantities into the ZSK twin screw extruder and reaches significantly higher throughput rates than before. This makes preheating via the mechanical energy input of the twin scews even more economical in chemical recycling processes.

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