The ZE 28 BluePower laboratory extruder for R&D applications and small batch production

At this year’s K exhibition in Düsseldorf, KraussMaffei Berstorff will exhibit a world’s first: the ZE BluePower laboratory extruder. This 28-mm twin-screw extruder ideally complements the ZE BluePower series presented three years ago in the small screw diameter range and offers a substantially extended process window for research and development applications as well as for small-batch production as compared to conventional laboratory-scale extruders.

State-of-the-art technology
“KraussMaffei Berstorff’s ZE BluePower is a future-proof twin-screw extruder series with numerous innovative features. This ZE version perfectly meets the ever increasing requirements in terms of overall equipment efficiency (OEEplus) of processing and R&D companies, in particular when it comes to energy efficiency, cost-effectiveness, equipment availability, performance and product quality,” says Peter Roos, President of the Extrusion Technology Segment and of the KraussMaffei Berstorff brand. “The newly developed laboratory extruder features numerous details of the ZE BluePower extruder series, e.g. the Do/Di diameter ratio of 1.65 for large free volume, the time-tested 4D and 6D housing elements for maximum flexibility and pressed-in liners for optimum wear protection. Our new laboratory extruder is rounded off by improved side feeding and degassing units, the new BPC-Touch control system, drive and control electronics integrated into the base frame as well as by an optional energy management tool,” declares Peter Roos.

Larger diameter = higher throughput rate
KraussMaffei Berstorff deliberately opted for a screw diameter of 28 mm for the lab-scale extruder. Together with the selected motor/gear combination rated for high torque density, the new extruder achieves a substantially enhanced performance when compared to the previous laboratory twin-screw extruder with a diameter of 25 mm. While the output rate can be increased by up to 43% with torque-limited processes, an up to 70% increase is even possible for processes that are limited in terms of volume.

The lab-scale ZE 28 BluePower extruder with a screw speed of up to 1,200 rpm is designed for output rates between 20 and 200 kg/h. Owing to its unparalleled flexibility, this extruder can be used for the most varied processing tasks. The identical design of all extruders within the ZE BluePower series allows the processing parameters easily to be up-scaled to a production line at any time. The laboratory extruder exhibited at K 2016 features a processing length of 44 D.

Newly developed side feeding and degassing units
The twin-screw side unit for lateral degassing (ZSA-E) is another highlight of the new laboratory extruder. It gives enhanced production reliability and higher equipment availability in particular with tacky and tough compounds that tend to rise in a vertical degassing dome.

In addition, the exhibited ZE BluePower laboratory extruder is equipped with a twin-screw side feeder (ZSA-D) of UltraFeed design for feeding fillers. Thanks to the vacuum created, this side feeder allows a high filler share to be fed into the extruder. The side units are usually fixed by means of a pivot-mounted arm to the extruder base frame to minimize the footprint and ensure easy handling.

State of the art BPC-Touch control system for easy machine operation and configuration
The new BPC-Touch panel that belongs to the standard equipment of all laboratory-scale extruders is another distinctive feature that gives maximum ease of operation. The intuitive BPC-Touch control software features a clear menu structure to reliably guide the machine operator through all process steps. All relevant peripheral components and downstream equipment can be rapidly tied into the software using standardized interfaces. Each operator is required to log in at the integrated transponders by RFID chip card. Depending on the user level, access to the assigned functions is granted. The control system completely records all steps performed by the operator.

UltraGlide feature for rapid screw removal
The exhibit is equipped with the time-tested UltraGlide feature, which allows the filled screws and the drive block to be removed backwards from the stationary processing section. Special benefits offered by this solution are that the compounding process can be rapidly inspected and evaluated and screw elements can be replaced without the need to disassemble the downstream equipment.

“The development of the new laboratory scale extruder was focused on optimizing overall equipment efficiency. The “plus in cost-effectiveness” that makes all the difference in terms of improved quality, enhanced performance and extended equipment availability decisively determines the return on investment of research and development laboratories and compounding companies”, explains Peter Roos.

Source: KraussMaffei Berstorff