Coperion Debuts at K2025: Efficiency Upgrades for Compounding and Recycling Processes with ZSK and STS Twin Screw Extruders

Improving efficiency is the core focus of Coperion's research and development work in the twin-screw extrusion field. Coperion's appearance at the K Fair 2025 will also emphasize enhancing mixing and recycling efficiency. At booth 14B19 in Hall 14, Coperion will showcase a ZSK 58 Mc.¹⁸Twin-screw extruder. This extruder has a screw diameter of 58mm and features low energy consumption and high automation, capable of achieving a production capacity of up to 2,500 kg/h. In addition, Kebelon will also showcase an STS 35 Mc at the same booth.¹¹The twin-screw extruder has been specially optimized for masterbatch production. At the Recycling Pavilion FG/CE07 in the open area, Coperion will demonstrate the added value of its twin-screw extruder in plastic recycling applications. Also on display will be the patent-pending ZSK FilCo filter-compounding unit.

The ZSK and STS twin-screw extruders from Coperion excel in high performance. Both extruders feature a very high specific torque - ZSK Mc.¹⁸The torque ratio is 18 Nm/cm.³；STS Mc¹¹The specific torque is 11.3 Nm/cm.³The torque is transmitted directly to the twin screws in the processing section through the gearbox and screw spindle, allowing for very high production rates in an economical and efficient manner when processing products with torque requirements. Additionally, due to the high filling rate in the processing section, the mixing quality is also outstanding. Combined with the high level of automation in these two extruder series, the unit cost for blending modification is relatively low, resulting in a quicker return on investment. These extruders are very durable, with high equipment stability, uptime, and OEE (Overall Equipment Efficiency).

Coperion will showcase the ZSK 58 Mc equipped with new screw elements.¹⁸The extruder, these threaded components were specifically developed by Kebelong for processing fillers. These threaded components can reduce wear in the melt zone while increasing output.

In terms of compounding and recycling, the Coperion ZSK 58 Mc¹⁸The twin-screw extruder, with its numerous innovative features, offers exceptional product quality and very high output.

The STS 35 Mc exhibited this time.¹¹The extruder is particularly suitable for the production of masterbatches. It can achieve a production capacity of up to 300 kg/h. The closely intermeshing twin screws ensure absolute uniform distribution of the materials while ensuring effective self-cleaning of the processing section. The compact design and smooth machine surfaces make cleaning and maintenance during formula changes very easy. STS 35 Mc¹¹It stands out for its very high process stability and attractive cost-effectiveness. It will be showcased along with a Coperion AccuRate® Series 602 volumetric feeder.。

Coperion has expanded itsC-BEYOND is a digital platform used to capture and display the operating data of extruders. C-BEYOND can obtain real-time assessments of key performance indicators (KPIs) such as equipment availability, output, and product quality. The production process is documented in detail, and the energy consumption and carbon dioxide emissions per kilogram of blended material can also be calculated. In the Overall Equipment Effectiveness (OEE) tool, the efficiency of the production line is displayed in real-time, allowing operators to quickly respond to deviations.

Coperion has expanded its digital platform C-BEYOND by adding a lifecycle manager, which is capable of notifying in advance about upcoming maintenance tasks for all components of the ZSK extruder.

C-BEYOND's new feature is the Lifecycle Manager, a component capable of enabling predictive maintenance scheduling to improve the production line's OEE. In the Lifecycle Manager, upcoming maintenance and repair tasks for all components of Coperion extruders are calculated based on operating hours and performance, and reports are generated in advance. For example, if gearbox maintenance is due soon, C-BEYOND will trigger a notification.

With the use of a lifecycle manager, maintenance and care work can be easily integrated and scheduled in advance, minimizing the impact on the high productivity of Coperion extruders. Once successfully executed, any maintenance measures are recorded in C-BEYOND and can be viewed at any time, accompanied by reports. As a result, a detailed maintenance history is generated for each machine during its service life.

The lifecycle manager has proven its effectiveness in practice on multiple pilot devices. Through this new tool, customers of Koberlin have already been able to significantly improve the overall equipment efficiency of their machines.OEE）。

Coperion will showcase its new extruder condition monitoring system for the ZSK 58 Mc at the K Show.¹⁸By utilizing motors, gearboxes, and sensors on the processing section, the system continuously monitors the vibrations of the extruder and gearbox, as well as the condition of the lubricants. It detects the first anomalies in operation at an early stage. Within the scope of the service agreement, KEBILON is responsible for remotely monitoring and evaluating the collected data, providing action recommendations to achieve proactive maintenance and reduce unplanned downtime. The condition monitoring system can be integrated into both new and old machines and has proven its reliability in numerous applications.

In the open area of the recycling pavilion FG/CE07, the ZSK extruder exhibited by Coperion is suitable not only for compounding but also for plastic recycling. Compared to the single-screw extruders commonly used in the plastic recycling industry, the ZSK twin-screw extruder stands out with its very strong mixing performance, excellent devolatilization capability, and high mechanical energy input, which shortens the residence time in the processing section. The product handling is very efficient and gentle. It achieves excellent product quality in the recycling of post-consumer mixed waste and industrial waste such as edge trims or sprues, with a throughput of up to 25 t/h.

These achievements are already being recovered.The quality of EPS foam has been confirmed in these aspects. The ZSK twin-screw extruder produces top-quality EPS—up to 30% of recycled EPS material can be added during the EPS production process without affecting the final product quality. Similar achievements have also been realized in Coperion's food-grade bottle-to-bottle recycling line, where the recycled and pelletized PET undergoes solid-state polycondensation (SSP) in a reactor—a process that has been approved by the European Food Safety Authority (EFSA) and the U.S. Food and Drug Administration (FDA) for direct food contact and has been certified by major beverage brands. One of Coperion's bottle-to-bottle recycling demonstration plants uses the ZSK 133 Mc.¹⁸The extruder has a production capacity of up to 6500 kg/h. With Coperion's solution, the production capacity can reach up to 10 t/h. Through the ZSK FilCo, Coperion will showcase its specially designed recycling extruder: this filtration and compounding unit can achieve filtering and modification of recycled materials in a single process step and single-stage equipment. Compared to the two-step method and two-stage equipment, the required space is significantly less. The plastic only needs to be melted once during the recycling and modification process, making the production process more energy-efficient and the product quality superior.