Compounding and Extrusion

| page 1
Twin screw compounder ZSK and STS

- perfect performance and economic solution
Dipl.-Ing. Roland Elsaesser,

Sales Manager Compounding&Extrusion, Coperion GmbH Stuttgart
Jakarta 2014 | page 2

Content
• Company information
• ZSK Mc18 – technology, key figures, design
• ZSK MEGAvolume PLUS
• STS Advanced
• Service
• Summary

Content
• STS Advanced
• Service
• Summary

Company history
Werner & 1879 1957

Pfleiderer Foundation First ZSK twin
Werner & screw extruder
Pfleiderer 2001 2007/2008
Merger to form the Realization of the
Coperion Group world´s largest
plants for polyolefin
2002 production
Waeschle 1900 1955
Foundation Bulk materials
ZSK NT
development
2008
Waeschle processing in the Brand 2012
consolidation / Hillenbrand, Inc.
plastics industry
Hartmann 2007 merger to form acquires Coperion
Acquisition and Coperion
integration into the
Coperion Group
2010
Successful
2004 launch of ZSK Mc18
Keya Acquisition and series
integration into the
Coperion Group
2012
Majority stake
PELL-TEC in PELL-TEC Coperion part of the
Process Equipment
2012 Group
Majority stake
in Weicom
Weicom

Hillenbrand, Inc.
Process Equipment Group

Coperion worldwide
Headquarters
Stuttgart, Germany
Competence Center
Compounding & Extrusion
Stuttgart, Germany
Materials Handling
Weingarten, Germany Coperion companies and
offices
Service
Stuttgart / Weingarten, Germany Agencies

Facts and figures
Key figures of Coperion
Compounding systems installed worldwide, over 10,000
Bulk materials handling systems installed worldwide, over 8,000
Employees worldwide, over 1,700
Network of locations worldwide 29

Coperion Twin screw compounders
- Portfolio
ZSK series Mc18: Md/a3 < 18 Nm/cm3 Mv PLUS: Md/a3 < 11.3 Nm/cm3
STS series Md/a3 < 10 Nm/cm3 CTE / CKY series Md/a3 < 5.6 Nm/cm3

Content
• STS Advanced
• Service
• Summary

General twin screw extruder layout
Feed
Motor Safety clutch Gear box Shaft coupling Barrels Screws Die head
Drive section Process section Discharge

Self-cleaning screw profile

Self cleaning intermeshing twin screw
Working principle

Screw Elements.
H1 > H2 > H3
Conveying V V V
elements
Kneading
elements
Mixing
elements
Left-handed
elements

Design criteria of twin screw compounders
Do = Outer diameter
Di = Inner diameter
a = Centerline distance
Do Do / Di = Diameter ratio
determines shear, degassing and powder intake
Md / a3 = Specific torque
determines power density and filling degree
Di n = Screw speed
a determines shear and mixing
Do / Di = 1,5 to 1,6
Md / a3 ≥ 11,0 Nm/cm3
n ≥ 800 min-1

ZSK – evolution of torque and volume
1955: ZSK Standard
Do / Di = 1,22
Md / a3 = 5,0 Nm/cm3
Increase of
free volume
and of specific torque
1970: ZSK variable
Do / Di = 1,44
Md / a3 = 5,0 Nm/cm3
Increase of free volume

1985: ZSK Supercompounder (additional 40%)
2001: ZSK MEGAvolume
Do / Di = 1,55 Do / Di = 1,80
Md / a3 = 8,7 Nm/cm3 Md / a3 = 8,7 Nm/cm3
Increase of torque
1995: ZSK MEGAcompounder
Do / Di = 1,55 2007: ZSK MEGAvolume
Md / a3 = 11,3 Nm/cm3 PLUS
Do / Di = 1,80
2004: ZSK MEGAcompounder Md / a3 = 11,3 Nm/cm3
PLUS
Do / Di = 1,55
Md / a3 = 13,5 Nm/cm3
2010: ZSK Mc18

Do / Di = 1,55
Md / a3 = 18 Nm/cm3

Series of Coperion twin-screw compounders
Taylormade
ZSK Mc18
Made by Coperion in Germany
(for world market)
Standard Twin-Screw / Two Stage

STS Advanced
made by Coperion (Nanjing), China
(for world market)
CTE and CKY machine series

made by Coperion (Nanjing), China (for China + Asia)

ZSK Mc18
The new dimension in compounding technology
Specific torque of 18 Nm/cm3

Do/Di = 1.55
Screw speed 1.200 min-1

Why Mc18-torque ?
Specific energy / shear: Influence of rate and screw speed
Low feed rate High feed rate High feed rate
Low screw speed High screw speed Low screw speed

barrel barrel barrel
Q2 Q2 Q2
Q1 Q1 Q1
h
screw screw screw
Average value
Shear rate
Shear rate
Shear rate
Average value
Average value
With higher torque, a higher fill grade can be realised.

The higher the fill grade, the lower the screw speed, the lower is the shear stress

ZSK Mc18
Most appropriate applications
For all torque limited processes like e.g.

• PP + 30 % GF
• PA 6.6 + 30 % GF
• PBT + 30 % GF
• ABS+PC + 20 % GF
• undried PET
• Higher output: as higher fill grades can be realised, which in parallel allows higher screw
speed with same average shear stress.
and/or
• Better product quality due to lower screw speed / higher filling degree / lower shear stress
/ lower melt temperature
and a lower specific energy consumption

ZSK McPLUS - Mc18
Increase in throughput

ZSK Mc - McPLUS - Mc18
Optimised price-performance ratio

ZSK Mc - McPLUS - Mc18
Reduced energy input with increased throughput

ZSK Mc18 – Features
Wear protection
hard cast chromium steel oval liners with

high wall thicknes and a solid apex area for sturdiness & long life

Liners are shrink fit for improved heat conduction
Liner

Direct coated surface
directly soldered, hiped

or welded wear- or
corrosion protection
surface

ZSK Mc18 – fully protected electrical manifold
• Assembly optimized parts groups

• Fully closed cable trays in IP54 or IP65
• Cable entry from bottom - no cable glands
• New heater cartridges „4-in-1“ with junction
box
• Heater cartridge can easily be replaced as
single part

ZSK Mc18 – new insulation covers
• New, user-friendly, segmented barrel insulation covers around the whole barrel!
• For optimum energy efficiency
„pampered“ insulation, even on the

bottom side!


ZSK Mc18
Technical data
Max. torque per Specific torque Max. screw Max. drive Screw diameter
ZSK
shaft [Nm] Md/a³ [Nm/cm³] speed [min-1] power N [kW] [mm]
18 MEGAlab* 38 11.3 1,200 10 18
26 Mc* 106 11.3 1,200** 28 25
32 Mc18 315 18 1,200 83 32
45 Mc18 930 18 1,200 246 45
58 Mc18 2,000 18 1,200 529 58
70 Mc18 3,500 18 1,200 926 70
82 Mc18 5,700 18 1,200 1,508 83
92 Mc18 7,500 17 1,000 1,654 92
106 Mc18 10,400 17 1,000 2,293 103
119 Mc18 15,300 17 1,000 3,373 118
133 Mc PLUS 18,100 13.6 1,000 3,791 133
* Laboratory extruder. ** max. 1,800 min-1 at reduced torque. ZSK 32 - ZSK 82 available in compact version.

ZSK Mc18
Max. Throughput (depending on process, raw materials and products)
ZSK 106

Content
• STS Advanced
• Service
• Summary

ZSK – evolution of torque and volume
1955: ZSK Standard
Do / Di = 1,22
Md / a3 = 5,0 Nm/cm3
Increase of
free volume
and of specific torque
1970: ZSK variable
Do / Di = 1,44
Md / a3 = 5,0 Nm/cm3
Increase of free volume

1985: ZSK Supercompounder (additional 40%)
2001: ZSK MEGAvolume
Do / Di = 1,55 Do / Di = 1,80
Md / a3 = 8,7 Nm/cm3 Md / a3 = 8,7 Nm/cm3
Increase of torque
1995: ZSK MEGAcompounder
Do / Di = 1,55 2007: ZSK MEGAvolume
Md / a3 = 11,3 Nm/cm3 PLUS
Do / Di = 1,80
2004: ZSK MEGAcompounder Md / a3 = 11,3 Nm/cm3
PLUS
Do / Di = 1,55
Md / a3 = 13,5 Nm/cm3
2010: ZSK Mc18

Do / Di = 1,55
Md / a3 = 18 Nm/cm3

ZSK MEGAvolume
MEGAvolume MEGAcompounder
- Do/Di= 1,8 - Do/Di= 1,55
ca. 40 % more free volume for compounding processes with
high torque demand
less shear stress due to - optimised ratio regarding
- deeper channels and Do/Di= 1,8 Do/Di= 1,55 mechanical strength vs. free volume
- smaller screw crests
Di
Do

ZSK MEGAvolume
Deeper screw channels offer advantages
- improved intake Do/Di = 1.8

v
- higher screw speed applicable u
- higher throughput
- reduced shear h
max
- lower stock temperatures ZSK Mv

- lower product stress
Shear rate gamma = vu /h
- improved product quality
- more reliabily venting performance
Do/Di = 1.55
v
u
h'
max
ZSK Mc

ZSK MEGAvolume
Most appropriate applications
• for products with low bulk density

• for processes with low specific energy input (< 0,15 kWh/kg)

ZSK MEGAvolume
Example: max. throughput Powder Coating production
Machine ZSK 27Mv 34Mv 43Mv 54Mv 62Mv 76Mv

max. Capacity [kg/h] 160 350 750 1.200 1.600 3.200
max. Speed [rpm] 1.200 1.200 1.200 1.200 1.200 1.200

max. Power [kW] 27 54 112 214 329 600

ZSK MEGAvolume PLUS
Example: max. throughput Carbon Black - Master Batch
LDPE PP
LDPE
+ 40 % + 35 %
+ 40 %
RCF 30 nm particle RCF 20 nm particle
RCF 20 nm particle size
size size
[kg/h]
[kg/h] [kg/h]
ZSK 34 Mv PLUS 150 165 100
ZSK 43 Mv PLUS 300 330 200
ZSK 54 Mv PLUS 600 650 400
ZSK 62 Mv PLUS 930 1.000 620
ZSK 76 Mv PLUS 1.700 1.800 1.100
ZSK 98 Mv PLUS 3.700 4.000 2.500
ZSK 125 Mv PLUS 7.800 8.400 5.200

Content
• STS Advanced
• Service
• Summary

Series of Coperion twin-screw compounders
Taylormade
ZSK Mc18
Made by Coperion in Germany
(for world market)
Standard Twin-Screw / Two Stage

STS Advanced
made by Coperion (Nanjing), China
(for world market)
CTE machine series

made by Coperion (Nanjing), China (for China + Asia)

Coperion’s Standard compounding machines STS Advanced
Standard Twin Screw
additional series of co-rotating twin screw compounders
- well proven Coperion quality, ZSK MEGAcompounder screw geometry, Do/Di = ca. 1,55
- specific torque: 10 Nm/cm³
for standard compounding tasks:
- Engineering Plastics
- Masterbatch
- Recycling
- certified

Coperion (Nanjing) Machinery Co. Ltd.

Coperion (Nanjing) Machinery Co. Ltd.
Assembly hall
Production capacity
more than 450 machines
per year
(STS and CTE)
Coperion Nanjing Manufacturing
Machine assembly Assembly floor for control panels

Quality Control Incoming Goods
Chemical elements test for monitoring the raw materials quality
Test Equipment for Chemical elements analysis

Production Quality Control
3D Measuring System to Ensure Precise Dimensions

Strict control of manufacturing precision on barrels, gearbox houses and
screw couplings by 3D Measuring System

Factory acceptance test (FAT) with polymer
allows for fast and troublefree installation and start-up on customer‘s site
Factory acceptance test with product CE certification proper over-sea crating

Coperion Standard machine STS Advanced - Torque 10
Standard Twin Screw

STS Advanced type 35 50 65 75 96
screw diameter [mm] 35,6 50,5 62,4 71 93,6
Md/a³ 10 10 10 10 10
motor power [kW] 55 132 250 400 900
screw speed [1/min] 80-800 80-800 80-800 80-800 80-800
expected capacity [kg/h] 80-230 300-690 500-1.150 800-1.840 1.200-3.800
Number of STS Sold by Region
America
19%
Europe/Middle
East
Asia
17%
64%
almost 500 STS machines sold 2004 - 2014

Applications
Wood Plastic TPE Recycling

2% Others
Comp 5%
17%
5%
Masterbatch
20%
Engineering
Plastics
51%
total ≈ 500 STS

Twin screw compounder ZSK and STS –
perfect performance and economic solution
Content
• STS Advanced
• Service
• Summary

Service
Coperion’s three promises given with its service structure
Global operation Confidence Innovation
Customers‘ benefit

Spare parts service
With over 48,000 parts managed Coperion‘s warehouse is one of the largest in the industry. It
includes both original Coperion spare parts and parts from suppliers.
Spare parts produced to the highest production standards
Short delivery times and 24-hour express delivery service for

stock parts
Provision of substitute types for parts which are no longer
available
Gearbox and barrel replacement service
Emergency stock for the quick replacement of core

components
Screw and kneading elements

Twin screw compounder ZSK and STS –
perfect performance and economic solution
Content
• STS Advanced
• Service
• Summary

Summary
Coperion is the worldwide market and technology leader in Compounding & Extrusion,
Materials Handling and Services. We are a partner for global corporations as well as for small
and medium-sized enterprises in the plastics, chemical, food and aluminium industries.
Coperion has over 130 years of experience with mixing and kneading processes.
Pioneering work and continuous development of the closely intermeshing, co-rotating twin-
screw extruder. Our twin-screw compounders continually set new standards in the plastics,
chemical and food processing industries.
Over 10,000 compounding systems are installed worldwide.
30 compounding systems worldwide for testing.

More than 25 process specialists, high skilled technical support for our customers
Global service and suport.
Coperion – confidence through partnership

Your Contact in Indonesia
WAHANA MITRA ABADI
Mr. Bernadus Slamet
Jl. Telesonic
Komp. Pergudangan Surya Kadu
Blok I No. 10
Jatake - Tangerang
Phone: +62 21 2943 8030 +62 811 849706
+62 21 2943 8031 +62 817 0066675
Fax: +62 21 2943 8059 Email: bernadus@wahana-mitra.com

This document and all contributions and illustrations
contained there in are protected by copyright. Any use
there of beyond the scope of the copyright without
editor’s prior written consent is illegal and will be
prosecuted. This shall in particular apply to translations,
reproductions, micro filming and processing in
electronic systems.
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Compounding and Extrusion

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| page 1

Twin screw compounder ZSK and STS

Dipl.-Ing. Roland Elsaesser,

Jakarta 2014 | page 2

Jakarta 2014 | page 3

Jakarta 2014 | page 4

Werner & 1879 1957

Jakarta 2014 | page 5

Process Equipment Group

Jakarta 2014 | page 6

Jakarta 2014 | page 7

Compounding systems installed worldwide, over 10,000

Bulk materials handling systems installed worldwide, over 8,000

Employees worldwide, over 1,700

Network of locations worldwide 29

Jakarta 2014 | page 8

Jakarta 2014 | page 9

Jakarta 2014 | page 10

Drive section Process section Discharge

Jakarta 2014 | page 11

Jakarta 2014 | page 12

Jakarta 2014 | page 13

Jakarta 2014 | page 14

Jakarta 2014 | page 15

Increase of free volume

2010: ZSK Mc18

Jakarta 2014 | page 16

Standard Twin-Screw / Two Stage

CTE and CKY machine series

Jakarta 2014 | page 17

Specific torque of 18 Nm/cm3

Jakarta 2014 | page 18

Low feed rate High feed rate High feed rate

Low screw speed High screw speed Low screw speed

screw screw screw

With higher torque, a higher fill grade can be realised.

Jakarta 2014 | page 19

For all torque limited processes like e.g.

Jakarta 2014 | page 20

Jakarta 2014 | page 21

Jakarta 2014 | page 22

Jakarta 2014 | page 23

hard cast chromium steel oval liners with

Jakarta 2014 | page 24

Jakarta 2014 | page 25

directly soldered, hiped

Jakarta 2014 | page 26

• Assembly optimized parts groups

Jakarta 2014 | page 27

„pampered“ insulation, even on the

Jakarta 2014 | page 28

Jakarta 2014 | page 29

Jakarta 2014 | page 30

Jakarta 2014 | page 31

Jakarta 2014 | page 32

Increase of free volume

2010: ZSK Mc18

Jakarta 2014 | page 33

Jakarta 2014 | page 34

- improved intake Do/Di = 1.8

- lower stock temperatures ZSK Mv

Jakarta 2014 | page 35

• for products with low bulk density

Jakarta 2014 | page 36