Processes APIs and Solid Dosage Forms

The ZSK Pharma Twin Screw Extruders from Coperion are engineered to enhance the continuous processing of active pharmaceutical ingredients (APIs) and solid dosage forms. Featuring a modular design, these extruders provide flexibility in processing with adjustable barrel and screw configurations, ensuring precise mixing and controlled temperatures to prevent API degradation. Ideal for producing controlled-release tablets, sustained-release capsules, and transdermal drug delivery patches, they are instrumental in pharmaceutical applications requiring high levels of dispersion and encapsulation. The ZSK Pharma Extruders offer specific torque of up to 18 Nm/cm³, accommodating high throughput while maintaining product integrity. Integrated with PLC control systems that comply with CFR Part 11, they facilitate seamless automation and easy scale-up from R&D to full-scale production. Constructed in GMP-compliant stainless steel with FDA-compliant lubricants, these extruders ensure reliability and safety. The self-cleaning twin screws and compact design allow for quick operation, reduced maintenance, and minimal space requirements, supported by Coperion’s extensive engineering expertise and after-sales service network.

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Streamlines Filtration and Compounding in Recycling

The ZSK FilCo Filtration Compounder by Coperion revolutionizes recycling with a unique system that integrates filtration and compounding into a singular production step. Designed for polymer processors and recyclers, this equipment simplifies the processing of post-consumer recyclate and highly contaminated polymers. Working with the ZSK twin screw extruder, the ZSK FilCo melts, homogenizes, and devolatilizes plastic waste before filtering out contaminants. This processed melt is reintroduced for compounding with various fillers or reinforcing materials, such as glass or carbon fibers.

Applications span across the recycling of diverse plastics, culminating in high-quality products like pelletized plastic recyclate and fiber-reinforced composites. This system notably reduces energy consumption and emissions by over 50% compared to traditional methods, due to its streamlined design that eliminates the need for multiple melting processes. The ZSK FilCo handles solid, granule, and film flake inputs, all while maintaining continuous, high-speed operation. Compact and efficient, it offers consistent quality improvements and reduced thermal stress on polymers, making it a crucial asset for sustainable materials manufacturing.

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Processes Low Bulk Density Materials Efficiently

The ZSK Mv PLUS Twin Screw Extruder from Coperion is engineered to enhance productivity for industries facing the challenge of processing products with low bulk density. This extruder series stands out with its large free screw volume, high screw speeds, and significant specific torque, making it versatile for applications like plastics compounding, chemical processing, and pet food production. By achieving high throughputs at specific energy requirements under 0.13 kWh/kg, it increases plant productivity and formulation flexibility significantly.

Designed for continuous, high-speed operations, the ZSK Mv PLUS handles applications ranging from masterbatches and polyolefins to bioplastics and battery materials. It can support throughput rates up to 40% higher than its predecessors. The extruder’s robust automation and integration capabilities feature user-friendly control systems and electronic maintenance openings for minimized downtime. The equipment also offers various wear protection solutions and corrosion-resistant material options to meet specific process demands.

Moreover, its innovative Feed Enhancement Technology (FET) and side devolatilization systems ensure efficient processing of shear-sensitive and filler-rich materials. Coperion backs this extruder with comprehensive process engineering support and a global service network, offering customized solutions to match your facility’s precise needs. Whether you are in plastics recycling, battery manufacturing, or food processing, the ZSK Mv PLUS delivers reliable, cost-effective, and scalable extrusion solutions.

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Compounds and Pelletizes Plastic and Chemical Materials

The CTE PLUS series from Coperion Nanjing offers a robust twin screw extruder solution designed specifically for the needs of small to medium-sized manufacturers in the plastics and chemical industries. These systems are distinguished by their modular design and the precision engineering of Coperion Stuttgart, ensuring reliable compounding and pelletizing of diverse materials, such as engineering plastics and cable compounds.

Utilizing closely intermeshing, co-rotating twin screws, these extruders efficiently mix, degas, and form materials into a consistent high-quality output, suitable for end-products including polycarbonate sheets, thermoplastic elastomer grips, and low smoke halogen-free cables. Each model, such as the CTE 50 PLUS, balances cost with performance, offering a specific torque of 7.2 Nm/cm³ and throughput rates from 30 kg/h to 5,000 kg/h, depending on the model size.

The CTE PLUS is adaptable, featuring flexible process section configurations and readily integrates into existing production lines with its advanced control systems ranging from simple relay controls to sophisticated PCC systems for real-time line management. Each machine adheres to strict quality standards with a Factory Acceptance Test at Coperion’s Nanjing site, ensuring dependable operation and high process safety supported by new gearboxes designed for longevity and performance. Ideal for compounding processes requiring precise formulation, this series provides significant energy efficiencies and can be tailored with TÃœV CE certification for validated operations.

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Processes Diverse Food and Pet Food Products

Coperion’s ZSK Mv PLUS Twin Screw Food Extruder offers versatile processing for food and pet food manufacturers by allowing continuous extrusion of products such as plant-based proteins, snacks, and confectioneries. The equipment features co-rotating screws with a self-wiping profile, ensuring high conveying efficiency and self-cleaning. Its modular design supports varied applications by adjusting free screw volume, speed, and torque, accommodating both laboratory and production-scale operations. Capable of processing various solids, powders, and granules, it enhances operational efficiency with speeds up to 1,800 rpm. The ZSK Mv PLUS operates with a specific torque of 11.3 Nm/cm³, delivering up to 40% increased throughput compared to previous models. Constructed from stainless steel, it ensures hygienic and easy-to-clean surfaces, reducing downtime. Additionally, it supports hybrid versions, enabling the production of both dry texturized vegetable proteins and high moisture meat analogues with customization options and engineering support available to meet unique production needs.

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Pelletizes and Cuts Extruded Materials

The Centric Pelletizer ZGF Series from Coperion is engineered to enhance pelletizing efficiency for a wide range of industries, including food, pet food, chemicals, and pharmaceuticals. What sets this equipment apart is its precise knife rotor system, which centrally aligns to the die plate, cutting extruded products directly at the end of the extruder. This configuration ensures uniform pellet length and maintains high product quality. Ideal for producing cornflakes, fish pellets, dog kibble, polymer pellets, and pharmaceutical tablets, the series supports continuous, high-speed operations with adjustable pellet length through variable knife speeds. The ZGF Series integrates seamlessly with twin screw extruders, connected via quick release mechanisms for fast assembly and disassembly, minimizing downtime in your production line. Its stainless steel construction provides corrosion resistance, suitable for various operational environments. Moreover, the pelletizer comes equipped with a safety feature to ensure the hood remains closed until the motor stops, enhancing operational safety. Customization options, such as the number of knives and rotor speed, allow you to tailor the machine to specific production needs, supported by Coperion’s engineering expertise.

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