KraussMaffei Extrusion presents ZSA UltraCycle

KraussMaffei Extrusion will present the new ZSA UltraCycle, a side-feed system for twin-screw extruders developed specifically for recycling applications. The system enables direct and reliable processing of light, low bulk-density materials such as plastic flakes and fibers without additional pre-compaction. Integrated material compaction allows several process steps to be combined, simplifying the recycling process and reducing both energy consumption and capital expenditure. According to the company, this can significantly improve the cost-effectiveness of processing. The ZSA UltraCycle is designed for fluffy recycled materials that are difficult for conventional feeding systems due to their low bulk density of 10 kg/m³ or more and high volume. Examples include thin-walled flakes, film scraps and plastic fibers from consumer waste, as well as fibers from textile recycling. Typical materials include PET, (LD)PE and PP flakes, as well as fibers and fabrics made of PA and polyester.

Although the twin-screw extruder has sufficient processing capacity, material feed often limits the achievable throughput when processing such materials. The ZSA UltraCycle is intended to create the conditions needed to reliably use the existing processing capacity of the extruder.

Direct feeding without additional pretreatment

The new ZSA UltraCycle compacts lightweight and low bulk-density recycled materials during feeding, enabling continuous and reliable feeding of the twin-screw extruder. This eliminates 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 and flexible screw design

At the core of the newly developed side-feeding system are two screws with a special design that ensures efficient compaction of the material. This allows even large quantities of light recycled materials with 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 enables flexible adaptation to different materials and applications. The design also offers advantages in terms of wear. Individual screw elements can be replaced selectively instead of replacing the entire screw, reducing downtime as well as maintenance and spare parts costs.

Trials confirm 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 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, the potential savings amount to up to 400,000 kWh of electricity, or approximately 60,000 euros per year, assuming an energy price of 0.15 euro/kWh.

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

KraussMaffei Extrusion will present the ZSA UltraCycle at Fakuma in hall A7, booth 7303.