Key Highlights
- Extruder manufacturers added features to hardware and software to make machinery easier to operate, addressing the challenge of skilled operator shortages.
- Coperion's Lifecycle Manager enhances equipment effectiveness by predicting maintenance needs and reducing downtime through digital monitoring.
- Milacron's MosaicX control system now offers faster data processing, customizable interfaces, and improved fault diagnostics for better operational control.
- Battenfeld-Cincinnati introduced a double degassing system (DVT) and a water supply system that reduces pre-drying costs and allows processing of untreated regrind materials.
- KraussMaffei launched the ZE Petrochemical series for large-scale applications, featuring high torque, modular screw sizes, and energy-efficient operation.
By Ron Shinn
Extruder manufacturers at K 2025 added interesting new features to both hardware and software, generally designed to make their machinery easier to operate at a time when skilled operators are difficult to find.
Coperion expanded its C-Beyond digital platform by adding a Lifecycle Manager function for predictive maintenance planning. The new function helps increase overall equipment effectiveness (OEE).
Milacron showed the latest version of its 19-year-old Mosaic control system labelled MosaicX. Diagnostic and fault-finding capabilities have been improved to provide quicker problem identification and solutions.
KraussMaffei improved its Pioneer ProcessControl (ppC) system by adding data through widgets and dashboards in a way that is useful to operators at all skill levels.
Battenfeld-Cincinnati showed two new hardware technologies. One is a single-screw extruder with new Dual Vent Technology (DVT) where degassing takes place in two different areas of the processing unit. The second is an internal water supply that eliminates the need for external water supply.
Here are the details.
Coperion’s new models for compounding, recycling
Coperion introduced two new models to existing twin screw extruder lines, one primarily for compounding and the other for recycling, and showed new features to its C-Beyond digital platform.
The ZSK 58 Mc18 twin-screw extruder has a 58mm screw diameter. Throughput is up to approximately 5,511 pounds per hour with low energy consumption and a high degree of automation.
Coperion said the machine’s high torque makes it a good choice for processing engineered plastics. It has an outer diameter-to-inner diameter ratio of 1.55. Maximum torque per shaft is 2,000 Newton meters (Nm).
Torque is directly transferred via the gearbox and screw shafts onto the rotating twin screws. Coperion said the cost per pound of compound is low, due to the high output and the machine’s standard automation features. That gives a quick return on investment.
The ZSK 58 Mc 18 uses gentle processing with a higher filling degree to improve compound quality.
The STS 35 Mc 11 twin screw has been optimized for masterbatch processing and has a maximum throughput of approximately 661 pounds per hour. Coperion said the closely intermeshing twin screws allow for even material distribution of ingredients and provide self-cleaning in the process section.
With its higher torque, the new machine delivers up to 27 percent higher throughput rates than the previous model. Greater screw fill results in a decrease of melt temperature. The maximum torque per shaft is 305 Nm. Its maximum RPM is 900.
To improve cleaning and facilitate quick changeovers for masterbatch applications, the STS twin-screw extruder also features optimized hoppers with inserts and a redesigned die head.
The STS 35 Mc 11 uses brass heater shells and water flash cooling with flexible connection to water manifold for optimal processing conditions in every heating zone.
The process section is made from nitride-hardened steel.
The company lists recycling of regrind plastics as a target use for this extruder. Coperion builds the STS Mc 11 line in China.
Coperion also showed its Lifecycle Manager feature for predictive maintenance planning for the first time. The Lifecycle Manager is part of the C-Beyond digital platform, which captures and displays the extruders’ operational data.
The Lifecycle Manager uses an extruder’s operating hours and performance to compute upcoming maintenance and repairs for all the machine’s components. When a service is coming due or a repair is needed, C-Beyond sends a notification to the operator.
Coperion said the Lifecycle Manager improves a machine’s OEE because service and maintenance can be bundled and scheduled to minimize downtime.
Service and maintenance work is logged in the Lifecycle Manager to create a maintenance record over the machine’s life.
Coperion also demonstrated a new extruder condition-monitoring system on the ZSK 58 Mc18. It uses sensors in the motor, gearbox and process section to monitor vibrations and detect anomalies.
Coperion offers a service agreement to remotely monitor, capture and evaluate sensor data and recommend actions.
Milacron upgrades Mosaic control system
Milacron rolled out the latest version of its well-known Mosaic extrusion control system called the MosaicX.
The latest version has more standard features, faster processing speeds that enable more data collection and report generation, plus custom screen options that can provide simultaneous views of multiple machine functions.
It is capable of controlling multiple extruders, downstream equipment and auxiliary systems.
The Mosaic platform was first introduced in 2007.
MosaicX has a 21.5-inch HD screen. The system offers graphical process monitoring for more than 50 parameters. Data protection with four access levels for up to 30 machine operators is standard, and RFID login is available as an option.
Data transfer, including mold data and screen shots, is through USB keys. The change log and alarm log can be stored on the control, a USB stick or network drive.
The operating system is Windows-based. A remote-mounted IP camera interface is optional.
Real-time monitoring provides live updates on extruder motor pressure. The controller also allows for adjustable back-pressure settings. Extruder RPM steps from 1 to 5 can be set for tailored operational efficiency.
Milacron said self-diagnostic and fault-finding capabilities have been improved to provide quicker problem identification and resolution.
MosaicX supports three languages: English, Spanish and French.
It can be retrofitted to older Milacron extruders.
Battenfeld-Cincinnati has innovative degassing
Battenfeld-Cincinnati unveiled two extruders, its first single-screw extruder with DVT, plus the final machine in the solEX NG single screw series.
Unlike standard double degassing systems, which are located next to each other, Battenfeld-Cincinnati’s new DVT system has two independent degassing areas along the extruder’s processing unit. The company said this arrangement more effectively removes gasses.
On display was the BC 120-40 DVT model.
The redesigned screw does not change the operation of the single-screw extruder, said René Hartmann, regional sales manager at Battenfeld-Cincinnati, in a news release.
The DVT system removes volatile substances with low partial pressure from the melt in the first degassing zone. Substances with higher partial pressure are removed in the second zone. Hartmann said this removes significantly more moisture than systems with a single degassing zone. It also prevents bubble formation.
“For the processing company, this means, on the one hand, that it hardly needs to pre-dry its material, thus saving on equipment and associated acquisition and energy costs,” Hartmann said. “On the other hand, the new double degassing extruder allows them to use untreated residues and regrinds and still extrude high-quality semi-finished products.”
The solEX NG 105 is being added to fill a gap in the single-screw extruder line. The line includes the 45, 60, 75, 90 and 120 models. The 105 has a throughput range of 3,700 pounds per hour to 4,630 pounds per hour.
The solEX NG 105 is equipped with a newly developed internal water supply that needs to be filled only once with water and chemicals to control corrosion. This system prevents impurities from outside water clogging cooling channels. Also, cooling water reaches the components at a constant, low temperature.
Low cooling water temperature increases the lifespan of the engine and gearbox, a company spokesman said. Plans are for this system, which is mounted on the side of the extruder, to be added to all extruders in the future.
SolEX NG extruders have a processing unit consisting of an internally grooved barrel in combination with a matching screw and grooved bush geometry, resulting in reduced axial pressure and machine wear.
The solEX NG models achieve about 25 percent higher output when processing HDPE and up to 40 percent higher output with PP, according to the company.
KraussMaffei upgrades popular ZE BluePower line
KraussMaffei launched an entirely new extruder line, the co-rotating twin-screw ZE Petrochemical (ZE-PC) series, designed for a wide range of applications, as well as new designs for the ZE BluePower series.
The German manufacturer said the ZE-PC machines are for melt-to-pellet, powder-to-pellet and large-scale industrial recycling operations.
The ZE-PC series comes in screw diameters ranging from 260mm to 400mm. It has a large outer diameter-to-inner diameter ratio (Da/DI) of 1.65 and high torque density.
“Petrochemicals is one of the fastest-growing markets worldwide,” said Ralf Benack, CEO of KraussMaffei Extrusion, in explaining why the ZE-PC was developed to get KraussMaffei into this market. “Our many years of experience with large-scale single-screw extruders — especially in the diameter range from 400mm to 800mm — and the successful BluePower series, have laid the foundation for us to now also enter the raw polymer production market with our own twin-screw solution.”
The ZE-PC series is equipped with a variable-speed drive.
Low screw speeds reduce the risk of thermal degradation of the material. Lower melt temperatures make higher throughputs possible and provide a wider process window. KraussMaffei said throughputs range from 27 tons to 143 tons per hour.
Modular screw sizes include 260mm, 300mm, 330mm, 365mm and 400mm.
KraussMaffei said the ZE-PC machines are designed for wear-resistance, low energy consumption and lower operating costs.
The company said a petrochemical group in China has already ordered three ZE-PC 330 machines.
The redesigned ZE BluePower compounding line offers improved operation and greater energy efficiency, digital networking via the Pioneer ProcessControl (ppC) system, optimized price-to-performance ratio and shorter delivery time.
The ppC system has an improved design to deliver data through widgets and dashboards, making key production values easy to read and providing intuitive, abstract visualizations of the entire production process. A role-based interface provides accessibility for all operator skill levels, while process-oriented navigation and smart guided workflows simplify complex production steps.
The modular machine series integrates easily with additional components, including feeders, vacuum pumps, melt filters, granulators and extrusion heads, the company said.
Screw diameters range from 28mm to 186mm. Da/DI is 1.65.
KraussMaffei’s UltraGlide system for easy screw removal is an available option.
The redesigned unit handles a wider range of formulations, including high filler loads, recycled content and sensitive polymers.
KraussMaffei said that for sheet, the redesigns mean improved melt homogeneity that minimizes thickness variations and surface defects, reduces scrap and boosts downstream yields. For pellets, stable throughput results in clean pelletizing and consistent additive dispersion. For profiles, dimensional accuracy and surface quality are improved, while modular screws support frequent product changes without extended downtime.
The ZE BluePower line was first introduced in 2013.
Contact:
Battenfeld-Cincinnati, McPherson, Kan., 620-241-6843, www.battenfeld-cincinnati.com
Coperion Corp., Wytheville, Va., 276-228-7717, https://coperion.com/en
KraussMaffei USA, Florence, Ky., 859-283-0200, www.kraussmaffeigroup.com
Milacron LLC, Batavia, Ohio, 513-536-2000, www.milacron.com
About the Author
Ron Shinn
Editor
Editor Ron Shinn is a co-founder of Plastics Machinery & Manufacturing and has been covering the plastics industry for more than 35 years. He leads the editorial team, directs coverage and sets the editorial calendar. He also writes features, including the Talking Points column and On the Factory Floor, and covers recycling and sustainability for PMM and Plastics Recycling.