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Engineering Value
3
3 mm verkrzt
service life
convince by their unparalleled productivity
and cost-effectiveness
Technical data
Specialized machinery
for special tasks:
12 sizes with particular
benefits
Six of the 12 ZE machine sizes the ZE 25 UTX up to the
ZE 75 UTX are designed as UTX models. This design
concept is distinguished by its particularly compact layout
and the very high degree of operator friendliness and ease
of maintenance. The ZE UTX laboratory and small batch
extruder is available in A and R versions as well as in an
A/R combination and in Ultra Glide version. The Ultra Glide
has a drive unit, which enables the whole extruder drive
unit with both screws to be moved backwards, leaving the
processing section in place. This is done in less than one
minute and makes it possible to carry out a rapid and pre-
cise visual inspection of the current state of the process.
AUSKLAPPER AUEN
ZE 25 UTX
ZE 30 UTX
ZE 40 UTX
ZE 50 UTX
ZE 60 UTX
ZE 75 UTX
AUSKLAPPER INNEN
1 Drive train
extruder.
3 mm verkrzt
4 Side-feeders
The enlarged twin-screw side-feeder
unit gives increased throughput of solid
materials by reducing fluidization effects.
In addition, the larger unit handles the
product more gently.
3 8-shaped bore
The 8-shaped ZE UTX barrel bore is
induction hardened to provide the neces-
sary resistance to wear. An induction coil
is employed to ensure uniform protection
of the inner surfaces of the barrel bore;
expensive replaceable anti-wear liners
are thus no longer required.
4 Side-feeder
AUSKLAPPER AUEN
5 Base frame
ZE 110 UT
AUSKLAPPER AUEN
ZE 130 UT
ZE 155 UT
ZE 180 UT
ZE 230 UT
6 ZE twin-screw extruders
Process implementation with utmost precision
D/d = 1.46
D/d = 1.74
Two barrel section lengths for each employed to meet your process require- tions and processing materials. Barrels
screw diameter. ments in the finest detail. made of composite materials are the
Barrel sections and screw elements are ideal solution to satisfy the most strin-
designed in strict accordance with the The patented hardening method (DE 101 gent requirements in terms of wear pro-
building block principle. With various 122 95 B4) for the ZE UTX barrel bores tection. Where protection requirements
types and different specifications that can is unparalleled worldwide. Induction are less severe, nitriding steel barrels are
all be combined with great versatility, hardening of the figure 8 bore provides used. Costly anti-wear barrel liners are
there is virtually no limit to the barrel and excellent protection against abrasion and no longer required for the ZE UTX series.
screw configurations, which can be corrosion for different extruder applica-
Closed barrels Top-open barrels with Side-open and combination 6D liquid injection barrels
4D or 6D opening barrels
Closed barrels Top-open barrels with Side-open and combination Injection barrels
4D or 6D opening barrels
9
In the case of twin-screw extruders of the Barrel sections with an L/D ratio of 4 or 6 More than fifty screw element varieties
ZE UT series, wear protection for machine are available for the configuration of the for each extruder size.
sizes ZE90 UT and larger is accomplished modular processing section. These barrel KraussMaffei Berstorff screw element
by using solid nitriding steel barrels, sections are designed as range:
barrels with through-hardened CrMo open barrels for feed zones, c onveying elements with different
liners or barrels made of composite open barrels equipped with inserts for lengths and pitches, multi-start,
materials. The selection of the type of degassing, metering, injection zones or self-wiping, laterally sealing or with
wear protection depends on the applica- with measuring elements, pushing flight profile with increased
tion the extruder is used for and on the closed barrels, free screw volume
specific conditions of wear. combined barrels for horizontal side m ixing elements in different lengths
feeding of additives and for vertical k neading elements in different lengths,
venting. offsets and pitch angles
b arrier elements in the form of blister
Extract from the screw element range discs and back-pumping elements
3 2
1
5 5
1
7 6 7 6 6
To ensure the future success of your Benefit from KraussMaffei Berstorffs homogenizing of polymers with
company, KraussMaffei Berstorff process know-how. different viscosities
twin-screw extruders are tailored to the ZE twin-screw extruders are modification of plastics by mixing in
specific requirements of your products successfully used for a multitude of additives
and processes. Based on our in-depth different applications: melting, homogenizing and pelletizing
know-how in all plastics compounding incorporation of reinforcing agents and of powders with low bulk density, small
and extrusion applications and our fillers such as glass fiber, talc, carbon particle size and low internal friction
design skills as experienced machine fibers, calcium carbonate, barium continuous synthesis of TPU
engineering company, we supply sulphate, etc. removal of volatile matter such as
extrusion lines that are perfectly suited coloring, stabilizing water, monomers, oligomers, solvents,
to your recipes and production pro- production of different plastics and etc. (degassing)
cesses. thermoplastic/elastomer alloys concentration of polymer solutions and
(e.g. TPEs) reclaiming of solvents
production of masterbatch such as polymerization and post-condensation
pigments, flame retardants, blowing re-pelletizing of millbase, agglomerates
agents and filler concentrates and sheet and fiber scrap
5
1
8
7 6 6 7 7 7 9 7
ZE Basic series
The KraussMaffei Berstorff ZE Basic This makes the ZE Basic the lowest-
series price, best-value twin-screw extruder
All 4 extruders in the ZE Basic series are made by KraussMaffei Berstorff.
quality machines, designed, as the name To drive the ZE Basic, there is a choice
suggests, for basic processes. More of motors with 2 speed ranges, 600 and
than 80% of all the plastifying, filling and 900 rpm, to provide a high torque capacity.
reinforcing applications can be covered The special power divider system in
by the ZE Basic series to produce the the gearbox and the multi-spline shafts
highest quality products. In other words, ensure that the torque is safely trans-
machines for processes that can be ferred to the screw elements giving out-
carried out without the need for too many put rates, dependent on the particular
types of barrel elements and are thus process, of up to 2,700 kg/h. If you want
more economical to purchase. to optimize your production, it is not only
the technical design that will decide you,
but also the small space required by the
extruders in the ZE Basic series.
15
This is due to the fact that the auxiliary Short delivery times
equipment such as the temperature With KraussMaffei Berstorff ZE
controller, the lubrication unit and the extruders you can rapidly benefit from
electrical equipment are all neatly inte rationalization effects, substantially
grated into the extruder base frame. save space, execute a new customer
order within shortest time, modernize
In addition to its competitive price, this your machinery or get well prepared
KraussMaffei Berstorff product stands for the future. These extruders, built in
out for excellent performance. The ZE strict compliance with the building block
Basic extruder thus ensures rapid return principle, require only minimum engi-
on investment for standard compounding neering times. Our innovative logistics
applications. system involving sub-suppliers and
stocking of standard components make
The convenient price of our ZE Basic for rapid machine assembly and allowed
series is, of course, combined with the delivery time for the ZE Basic range
in-depth know-how and the extensive to be reduced to just a few weeks.
and competent service that only experts
in extrusion technology can offer. This
includes detailed engineering advice,
the use of sophisticated testing facilities
in our technical centers and 24-hour
KraussMaffei Berstorff customer service.
16 ZE twin-screw extruders
Focus on cost reduction
The ZE Basic with its D/d ratio of 1.55 Standard applications for the ZE Basic:
the best solution to implement standard plastifying and alloying of plastics
processes at convenient investment incorporation of fillers
and operating costs. incorporation of reinforcing and filler materials
incorporation of natural materials
production of additives or color masterbatch
coloring of plastics
manufacture of polymer blends
Reinforcing Filling
17
The screw configuration tailored 10, or 12 are used to ensure reliable wear The different screw elements with
to your standard processes. protection according to the requirements D/d = 1.55 of the ZE Basic series
The newly developed ZE Basic barrel of specific applications. complement each other in terms of
sections provide precise temperature function and are specially tailored to
control. By virtue of the inductive harden- The following barrel types are available standard compounding applications.
ing process employed, the heating and for the configuration of the modular pro- You can easily create the perfect screw
cooling bores are positioned directly cessing section: configuration for your process require-
adjacent to the processing chambers. open barrel sections for the feed zone ments:
The cooling is by carried out by water open barrel sections complete with conveying elements with different
injection, the heating by means of high- special inserts for degassing, metering, lengths and pitches, self-wiping
power electric heater cartridges, which liquid injection or measuring ports mixing elements in different lengths
ensures stable processing conditions. combi-barrel side feeding sections for kneading elements in different lengths,
Nitriding steel or induction hardened horizontal material feed and vertical air offsets and pitch angles
CrMo barrels with an L/D ratio of 4, 8, removal barrier elements in the form of blister
discs and returning elements.
Modular barrel section for the ZE Basic series MP elements
1
3
C
A B
D 3
4
6 22
5 6
25 26
23 24
3 mm verkrzt
System partnership Service range
KraussMaffei Berstorff trusts in system From advice on optimization of
partnership. Focus is on processes for production processes, installation and
which KraussMaffei B erstorff supplies commissioning of the plant, right
the core machine and the entire know- through to start-up and fine-tuning
how from the raw material up to the KraussMaffei Berstorff is your system
final product. KraussMaffei Berstorff is partner in all project stages.
ideally equipped to handle projects of any Plant engineering
size and type from single machines up Plant logistics
to complete turnkey plants. System Basic building and infrastructure
partnership, ensures maximum machine design
reliability thanks to Interface coordinating with third parties
Innovative technical solutions for Project management
each individual application Training, production supervision and
Adequate engineering resources maintenance
Professional project management
State-of-the-art project control
instrumentation
Qualified suppliers and partner
companies
The KraussMaffei Berstorff modular concept
KraussMaffei Berstorffs refined modular concept fulfils customers require-
ments at reasonable investment cost with a high degree of premanufacture
and rapid commissioning.
The advantages:
Significant reduction in project planning and execution with simultaneous
engineering
Better cost and quality control by extended pre-assembly
Early recognition of possible weak points
Comprehensive training of operators and maintenance personnel
Simplified and safe transport: the steel frame serves as packing case
Quicker on-site installation to no assembly of individual components
Simply constructed production workshops
no mezzanine for additional steelwork required
Substantially reduced total costs and closer control
of cost and timing of the entire project
10 mm verkrzte Klapp-Seite
From planning to production
Scope of machinery
KraussMaffei Berstorff as your system Or for film and sheet production
partner, is not only a consultant, but also Raw material handling
an engineer and manufacturer of all key Feeding of the individual components
components. Where else could you find Compounding
this complete continuity from process Sheet calibration by different
solutions right through to design and smoothing roll technologies
manufacture of the machinery? One-stop Winding
shopping for in-line solutions complex
and complete. For pellet production:
Raw material handling
Feeding of the individual components
Compounding
Pelletizing
Packaging and warehousing
1 Polymer 14 Weighing and bagging A Recycling
2 Filling or reinforcing materials 15 Underwater pelletizer B Rework
3 Additives 16 Heat exchanger C Resin blend
4 Twin-screw side-feeder 17 Water tank D Premix
5 Twin-screw extruder 18 Pellet drying E Big bag
6 Vacuum degassing 19 Bow screen
7 Strand die head 20 Agglomerate separator 12
8 Water bath 21 Diverter valve
9 Vacuum air knife 22 Slot die
10 Strand pelletizer 2 3 Smoothing roll
11 Classifier screen 2 4 Tensioning unit
12 Silo 25 Material accumulator 11
13 Silo loading 26 Winder 10
9
8
14
7
18
10 mm verkrzte Klapp-Seite
11
21
20
12
15 16 19
17 13
16
14
OEE Plus
Boosting cost-efficiency for you
High overall equipment efficiency (OEE) is a fundamental prerequisite
for your companys success. KraussMaffei Berstorffs product portfolio
comprises tailored machines and lines along with perfectly matched
services that increase the economic efficiency and the sustainability
of your production. Benefit from our proven know-how of extrusion
technology in any application.
KraussMaffei Group
Comprehensive expertise
Unique selling proposition Technology3
The KraussMaffei Group is the only pro-
vider in the world to possess the essen-
tial machine technologies for plastics and
rubber processing with its KraussMaffei,
KraussMaffei Berstorff and Netstal
brands: Injection Molding Machinery,
Automation, Reaction Process Machinery
and Extrusion Technology.
1.0 LD, 1st edition 10/13. EXT 001 A PRO 10/13 EN KraussMaffei reserves the right to make technical changes. Printed in Federal Republic of Germany
optimize your production and sharpen your
competitive edge by complete system solutions,
turnkey production lines and customized services.
Benefit from extrusion concepts that easily provide
the high flexibility needed for the manufacture of a
multitude of products today. Base your planning on
an extruder concept that guarantees high availability
throughout the entire lifetime.
www.kraussmaffeiberstorff.com