More Recycling. Fewer Process Steps: KraussMaffei Extrusion Presents New ZSA UltraCycle at Fakuma

At Fakuma, KraussMaffei Extrusion will present the new ZSA UltraCycle, a side-feed system for twin-screw extruders developed specifically for recycling. This development simplifies the process, reduces energy consumption and capital expenditure, and can significantly increase the cost-effectiveness of processing.

The ZSA UltraCycle enables the direct and reliable processing of light, low bulk-density materials such as plastic flakes and fibres without additional pre-compaction. The integrated compaction of the material allows multiple process steps to be combined.

It is specifically designed for fluffy recycled materials that pose challenges for conventional feeding systems due to their low bulk density of 10 kg/m³ or more and their high volume. These include, for example, thin-walled flakes, film scraps, or plastic fibres from consumer waste, as well as fibres from textile recycling. Typical materials include PET, (LD)PE, and PP flakes, as well as fibres and fabrics made of PA and polyester. Although the twin-screw extruder used has sufficient processing capacity, the material feed often limits the achievable throughput with these materials. The ZSA UltraCycle creates the conditions necessary to reliably utilise the extruder’s existing processing capacity.

Directly Into The Process – Without Any Additional Pretreatment

The new ZSA UltraCycle compacts the lightweight and the low-bulk density recycled materials during feeding, enabling continuous and reliable feeding of the twin-screw extruder. This eliminates the need for additional pre-treatment steps such as compacting or agglomeration. At the same time, material feeding, melting, compounding, degassing and filtration can be combined in one continuous process. This reduces the number of process steps and lowers both equipment and energy requirements.

“With the ZSA UltraCycle, we are strategically expanding our product portfolio for recycling applications. Many materials that previously required additional processing due to their low bulk density can now be integrated into the extrusion process more efficiently. This opens up new opportunities for our customers to make their recycling processes more efficient and cost-effective,” says Philip Cichy, Global Director of Sales at KraussMaffei Extrusion.

Efficient Compaction, Flexible Screw Design

At the heart of the newly developed side-feeding system are two screws, whose special design ensures efficient compaction of the material. This allows even large quantities of light recycled materials with a low bulk density to be reliably conveyed into the feed zone of KraussMaffei Extrusion’s ZE BluePower twin-screw extruder without compromising gravimetric dosing accuracy. The result is consistent throughput, high recipe accuracy, and stable process control.

The modular screw design also allows for flexible adaptation to different materials and applications. The design also offers advantages when it comes to wear: Individual screw elements can be replaced selectively instead of having to replace the entire screw. This reduces downtime and lowers maintenance and spare parts costs.

Technology Centre Confirms Energy-Saving Potential

Trials conducted at the KraussMaffei Extrusion Technology Center in Laatzen/Germany confirm the potential of the new solution. By eliminating additional pre-compaction steps and enabling the direct processing of low bulk-density recycled materials, energy consumption and operating costs can be significantly reduced. At an exemplary throughput of 1,000 kg/h, this results in potential savings of up to 400,000 kWh of electricity, or approximately 60,000 euros per year, assuming an energy price of 0.15 €/kWh.

With the ZSA UltraCycle, KraussMaffei Extrusion makes the processing of lightweight and high-volume recycled materials easier, more efficient, and more cost-effective. The new solution reduces the number of process steps and energy consumption, thereby opening up additional potential for recycling materials that were previously difficult to process.

Read more news from KraussMaffei here.

KraussMaffei
+44 (0) 1925 644100
Website
Email