Extruders & Compounding Machines

ZSK Twin Screw Extruders

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ZSK twin screw extruders from Coperion are the industry benchmark for high-performance compounding and extrusion. Designed for plastics, recycling, chemical, food and pharmaceutical applications, they combine maximum throughput, outstanding product quality and unmatched process flexibility.

Every single component of the ZSK extruder is an example of top class high technology. With the know-how and experience of the pioneers in the development of the co-rotating twin screw extruder we design every single process step of the ZSK extrusion system to meet your individual product requirements. As a result, you benefit from maximum throughput rates and highest product quality. 

The continuous research and development work of Coperion has made the ZSK co-rotating twin screw extruder into what it is today: A top-quality product at the highest technical level. It is the high-end, hightech heart of our processing plants and is continuously setting new standards in the plastics, plastics recycling, chemical, batteries, pharmaceutical and food industries.

The quality of the end product is the decisive factor in complex processes such as the processing of viscous materials. From raw materials feeding through conveying, melting, dispersing, homogenizing, devolatilizing, pressure build-up, filtering and pelletizing, we use our decades of experience and extensive know-how to adapt every process step exactly to your application.

The ZSK high performance extruder gives you a processing plant featuring maximum throughput rates, gentle handling of the product, optimum efficiency and highest reliability and robustness.

Twin screw extruders are industrial processing machines that continuously mix, melt, disperse and compound polymers, additives and fillers using two intermeshing screws.

Advantages of ZSK Extruders

  • Maximum power density
  • Gentle product handling for maximum quality
  • Maximum screw speed
  • Maximum efficiency and productivity
  • High reliability and proven technology
  • Excellent mixing behaviour
  • Maximum conservation of resources by high efficiency
  • Maximum flexibility in product changes and machine modifications
  • Optimum graduation of the machine sizes
  • Reliable scale-up
  • Large number of application-specific solutions to increase throughput and productivity, e.g. quick-release features, side devolatilization ZS-EG, Feed Enhancement Technology (FET)
  • Comprehensive process engineering support
  • Very wide range of wear protection solutions
  • Flexible solutions for control system
  • Comprehensive after sales services
  • Very long service life
  • Fast ROI (Return On Investment)
  • Low TCO (Total Cost of Ownership)

The Power of ZSK Technology, Driven by Coperion

With the extensive knowledge of the technology leader for the design of processing plants, we continuously develop and optimize every single detail of the ZSK. It is demonstrated by countless technical achievements and innovations which are all perfectly adapted to each other. They make the ZSK the ideal compounder for maximum flexibility, reliability and efficiency at maximum product quality and throughput requirements.

Find the right ZSK Twin Screw Extruder for Your Application

 

Compare the ZSK Models

ZSK MEGAcompounder

  • PP Throughput rates up to approx. 100 t/h
  • LLDPE Throughput rates up to approx. 125 t/h
  • HDPE Throughput rates up to approx. 135 t/h
  • LDPE Throughput rates up to approx. 80 t/h
ZSK Mc¹⁸
  • Continuous processes with high energy consumption
  • Processing of all previously torque-limited products such as polyamide with glass, PBT with glass, glass fiber-reinforced polypropylene
  • Reinforcement with glass, carbon and other fiber materials
  • Degassing of volatile components
  • Filling with talcum, calcium carbonate, sawdust or other fillers
  • Chemical reactions such as polymerization, polycondensation and polyaddition
ZSK Mv¹⁴
  • Processes with high volume requirement, e.g. for products with low bulk density, poor intake properties or high filler content
  • Devolatilization processes, e.g. in substances containing solvents
  • Processes with low energy consumption
  • Shear sensitive products (e.g. effect-pigment masterbatch)
Kombiplast
  • Soft PVC
  • Rigid PVD
  • Special compounds
Laboratory Extruder ZSK 18 MEGAlab
  • Small batches from 200 g
  • Throughput rates of up to 40 kg/h
ZSK FilCo
  • Recycling of post-consumer waste (PCR)
  • Recycling of any highly contaminated polymers
Compounding Plants
  • Complete solutions from raw material handling, feeding, extrusion, pelletizing, sifting, drying and cooling, right through to gentle conveying and bagging of the finished products
  • One contact and supplier – from engineering and production of key components to commissioning of the plant
ZSK Food Extruders
  • Pet food, treats, aquatic feed
  • Flours and starches
  • Cereals, snacks
  • Encapsulation processes
ZSK Pharma Extruders
  • Pharmaceutical Hot Melt Extrusion (HME)
  • Wet Extrusion of APIs as basis for granules for capsule filling
  • Extrusion of adhesives with APIs for transdermal plasters
  • Extrusion of adhesives for medical applications such as stoma

ZSK Auxiliary Equipment

For the highest level of product quality and productivity

Coperion offers comprehensive auxiliary equipment for its ZSK twin screw extruders. These application specific special solutions such as the ZS-B MEGAfeed, the Feed Enhancement Technology (FET) or the ZS-EG side devolatilization guarantee the highest level of product quality and productivity of our compounding and extrusion lines.

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C-BEYOND

Data-Based Efficiency in Compounding & Extrusion

The demands on modern compounding & extrusion processes are continuously increasing. Higher productivity, maximum plant availability, transparent production data, and sustainable use of resources are today crucial factors for economic success. User Coperion's digital platform C-BEYOND to increase transparency and efficiency in compounding and extrusion processes. 

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  • Plastics
  • Plastics Recycling
  • Chemicals
  • Batteries
  • Food & Pet Food
  • Pharmaceutical

Control Systems for ZSK Extruders

Coperion provides control solutions for twin screw extruder systems individually tailored to customers’ requirements ranging from standardized control systems to customized open control systems for complete compounding plants. The control systems can be easily integrated into customers’ Industry 4.0 environments and offer a large number of functions such as the full recording of production data, reporting, recipe management and much more. The clearly designed, user-friendly interface of the control systems increases the operational availability of Coperion processing plants.

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Minor ZSK Details with a Major Effect on Performance

Modular Design of ZSK Extruders

The process section of all ZSK series is designed as a modular system. It consists of several barrels in which the co-rotating screws operate. The advantage of this modular principle is ist maximum flexibility in compounding and extrusion. Our process engineers configure the barrels and screw elements individually to your applications. Different process zones are created alternately as required for conveying, plasticizing, mixing and shearing, homogenizing, devolatilizing and pressure build-up to benefit from highest product quality and maximum throughput rates.

The temperature of every barrel can be controlled separately. The heating is usually electric by means of heater cartridges and heater shells, the cooling is achieved by water. In addition, barrels can also be tempered with liquid or steam heating. Standard barrels and screw elements are made of nitrided steel or in the enhanced wear and corrosion protected version of appropriate materials.

ZSK Extruders: Diameter Ratio

The diameter ratio Do/Di, which determines the free volume of the twin screws in the process section is constant over all sizes of the respective ZSK series. In this way we ensure the reliable scale-up from the knowledge gained in the laboratory to fullscale production plants. Important parameters such as screw
configurations or product recipe contents can reliably be transferred from small to large ZSK sizes.

ZSK Extruders: Self Cleaning Screw Profile

The closely intermeshing twin screws of the ZSK series eliminate with their tight, self-wiping profile stagnant zones over the whole length of the process section. The effect is a constantly high degree of process reliability and optimum self-cleaning in the process section.

High Efficiency of ZSK Extruders

Coperion ZSK extruders operate at maximum efficiency. They achieve very high throughput rates and deliver the highest product quality - all at comparatively low energy consumption. With many years of experience and comprehensive know-how for the entire manufacturing process, we design the extrusion and compounding lines as well as each individual unit to work as efficiently as possible.

Latest Developments on ZSK Twin Screw Extruders

Feed Enhancement Technology (FET)

In the Feed Enhancement Technology (FET) the feeding zone of the ZSK is equipped with a porous, gas permeable wall and a vacuum is applied externally. The results of the FET equipment are considerably improved feed and throughput rates in the processing of feed limited products.

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ZS-B side feeder

The ZS-B twin screw side feeder enables the feeding of powder or pellet fillers and additives or cut glass fibers into the process section of the ZSK twin screw extruder. It features the self-wiping profile of the twin screws and eliminates stagnant zones in the screw flights of the extruder. It requires very little space due to its compact design. It can be mounted anywhere on the extruder’s process section with a side feed or combi barrel. In easy design the ZS-B permits much faster dismantling from the ZSK process section and the twin screws can be changed very simple.

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ZS-B MEGAfeed side feeder

The ZS-B MEGAfeed makes the processing of lightweight, very voluminous materials, significantly more economical. Thanks to the innovative design of the ZS-B MEGAfeed side feeder, materials with bulk densities starting as low as 20 kg/m³, which were previously considered feed-limited and therefore not economically processable, can be reliably fed in large quantities into the ZSK twin screw extruder.

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ZS-EG side devolatilization

With its large free cross section for the devolatilization, the ZS-EG keeps the melt reliably in the process section even at maximum specific torque. Throughput increases of up to 30% and considerably improved product quality are possible. The ZS-EG in easy design permits fast dismantling from the ZSK process section.

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Quick-release screw shaft coupling

For ZSK 26 Mc¹⁸  extruders Coperion has developed a patented quick-release screw shaft coupling that enables screw changes to be performed as quickly as possible. Cleaning times are reduced to a minimum when changing colors and recipes.

Die head

The die head for ZSK systems features optimum flow geometry. It ensures highest throughputs with gentle product handling and maximum heat transfer.

Quick-release clamps at feed hopper, degassing dome and atmospheric venting

The ZSK feed hopper is only clamped to the process section with bolts. It can be removed very quickly by simply loosening these bolts. Then the quick-release insert which protects the barrel wall from contamination can very easily be changed. For quick and easy cleaning, the degassing dome and the atmospheric venting are also equipped with quick-release clamps. The units can be removed by loosening just four bolts. In addition, the connection of the vacuum line on the degassing dome is equipped with a quick-release c-clamp.

Pluggable cartridge heaters

ZSK extruders up to size ZSK 92 Mc¹⁸ are equipped with pluggable cartridge heaters enabling efficient individual tempering within the interior of each barrel. They are individually connected using IP67 plugs and can be removed for maintenance in no time, no electrician needed.

Coperion ServiceBox

The Coperion ServiceBox is an integrated system for the online monitoring and logging of faults in your plant and components, ensuring trouble-free compounding with stable product quality. Our active start-up assistance and rapid expert support are the ideal solution for efficient production with reliable quality control.

Electronically Secured Maintenance Opening at Gearbox Lantern

Coperion VibeTrack Condition Monitoring System

Condition Monitoring

Coperion offers the option to equip the ZSK extruder with a condition monitoring system which ensures a high level of plant uptime, identifies irregularities early enough to avoid potential damage, and significantly improves planning capability for maintenance tasks. The extremely reliable and yet affordable VibeTrack system focuses on vibrations and gear oil condition.

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Customer-Centric Approach

Wear Material Portfolio

ZSK extruders are designed to excel in challenging applications.

Our team of experts in material science, process technology and engineering collaborate closely to develop the perfect material solution for your needs – one that offers maximum protection while also being economically viable.

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