Plastics technology

Melt-fed single screw extruders

Perfectly mix, optimally degas, and reliably cool with high throughput.

KraussMaffei Berstorff single-screw extruders feature a simple and robust machine construction, low need for maintenance, highest torques, and free structuring of the procedure part. Thanks to their variable expansion options, the single-screw extruders are used worldwide for a wide variety of process tasks.

Thus outstanding outputs and dimensions were achieved with the KE single-screw extruder. For example:

  • The world's largest screw diameter of 800 mm with throughputs of up to 74 t/h
  • Melt homogenization with Maillefer shearing parts in conjunction with intensive cooling
  • New standards for melt degassing in the manufacturing of bulk plastics

 

Discharge extruders

Discharge extruders
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Cooling extruders

Cooling extruders
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Degassing extruders

Degassing extruders
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Compounding - Extruders & extrusion lines

Modular twin-screw extruders for a dynamic market environment

Reliability, flexibility and high throughput rates – these are the most important requirements for state-of-the-art compounding solutions. With the four ZE BluePower, ZE Basic, ZE-UTXi and ZE Ultra Torque (UT) series, KraussMaffei Berstorff offers tried and tested twin-screw extruders that perfectly fulfill these expectations. The comprehensive twin-screw extruder portfolio from KraussMaffei Berstorff provides ideal solutions for the processing and extrusion of plastics and other basic materials, which can be almost exclusively composed of standard elements.

As a general contractor, KraussMaffei Berstoff optimizes compounding solutions in existing infrastructures or supplies factory-preassembled systems in modular form with auxiliary equipment. The coherent design of the KraussMaffei Berstorff compounding system offers decisive benefits - perfectly coordinated system components combined with high production quality ensures smooth compounding processes.

ZE BluePower twin-screw extruders - Boosting power and volume

The new ZE BluePower twin-screw extruder series stands out for numerous innovative features in terms of energy efficiency and process engineering in compounding. This series is designed to meet the most demanding market challenges as to output rate, product quality, process reliability and flexibility. Benefit from the multitude of energy-saving innovations and the perfectly matched components of the trendsetting ZE BluePower twin-screw extruder.

Thanks to the extremely versatile configuration of the processing section, the ZE BluePower can be perfectly tailored to your specific requirements in compounding engineering plastics, polyolefins, cable compounds, PVC, masterbatches as well for special applications.

Features
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Materials & Technical specifications
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Laboratory extruder / ZE 28 BluePower
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The ZE Basic compounding extruder stands out for maximum productivity, quality, reliability and cost-effectiveness

For many compounders, the ZE Basic series is the optimum investment into the future combining innovation and reliability in the best possible manner. Four ZE extruders of modular design with screw diameters between 42 and 77 mm provide increased efficiency and enhanced cost-effectiveness.

These extruders can be equipped with air- or water-cooled motors with three speed steps of 300, 600 and 900 rpm. Either nitriding steel or induction-hardened CrMo housings with an L/D ratio of 4, 8, 10, or 12 are used to achieve effective wear protection adapted to the specific process requirements. The C-clamp flange system shortens the barrel housing assembly and disassembly times.

The various screw elements of the ZE Basic series with an OD/ID = 1.55 ideally complement each other and are especially tailored to standard compounding tasks.

With specially adapted up and downstream components, such as various metering and pelletizing systems, the twin-screw extruders can be converted into complete lines.

ZE Basic extruders tailored to your application are the key to maximum production profitability.

 

Barrel elements
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Screw elements
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Process control
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Materials & technical specifications
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Applications
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ZE Performance

ZE Performance - an extruder from China for China 

The ZE Performance series optimizes your production through exceptional cost-effectiveness. Benefit from a high degree of automation and maximum ease of operation to achieve stable production conditions in different compounding applications and unique product quality. Thanks to its exceptional flexibility, the ZE Performance is a perfect alternative that enables polymer producers to get well prepared for continuously changing market requirements.
The series is a high-class product, all components are made directly by KraussMaffei Berstorff or in close collaboration with famous suppliers in China for the Chinese market.

Take a closer look at the ZE Performance series
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Technical Specifications
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ZE UTXi laboratory extruder for advanced development tasks

Research for the production of tomorrow

The ZE UTXi twin-screw extruders form a unique class for the highest quality and productivity requirements. These twin-screw extruders convince by well-thought-out solutions that fulfill process tasks, increase product quality and simplify operation.

Speed-up development processes decisively with the fast, removal of the screws from the rear side

In just a few seconds, the UltraGlide drive block allows the filled screws to be removed backwards from the stationary processing section. This makes it possible to evaluate all processing stages rapidly and reliably.

In addition, screw cleaning and replacement are substantially facilitated by the UltraGlide solution.

Trial cost reduction

Today, research laboratories and compounding companies must keep a close eye on costs in order to be able to handle their varied tasks. Through consistent cost-effectiveness and proven quality, the laboratory extruders of the ZE UTXi series help you to keep costs under control.

Because high ease of maintenance and efficient wear resistance in housing and screw elements ensure low maintenance cost in the long run.

Additional benefits at a glance:

  • Delivered ready-to-plug-in, commissioning within a few hours after delivery
  • C-clamp barrel housing connections - 70% time savings during barrel housing changes compared to conventional screw flange connections
  • Extensive range of barrel sections and screw elements
  • Compact movable unit with integrated control and temperature control system
  • Reliable high-performance drive
  • Reliable and clearly arranged control of all process tasks and machine configurations

The laboratory extruders provide all relevant process measuring data needed for an exact scale-up to production machines.

Machine design
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ZE-A or ZE-R
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Barrel elements
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Screw elements
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Materials & Technical specifications
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Process control
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Applications
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ZE 40 - ZE 75 UTXi

ZE UTXi twin-screw extruders set benchmarks in terms of flexibility

The ZE UTXi twin-screw extruders form a unique class for the highest quality and productivity requirements. These twin-screw extruders convince by well-thought-out solutions that fulfill process tasks, increase product quality and simplify operation.

The ZE-UTXi twin-screw extruders provide comprehensive configuration options, even for the unusual and challenging compounding applications. The available range of 4D or 6D housings with or without opening gives unparalleled flexibility. Depending on the requirements, the processing section can be equipped with various screw elements from the KraussMaffei Berstorff modular system. The result is a customized extruder enabling you to gain a leading market position and to be well prepared for the future.

Machine design
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ZE-A or ZE-R
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Barrel elements
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Screw elements
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Materials & technical specifications
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Process control
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Applications
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ZE 90 to ZE 230 UT

ZE Ultra Torque (UT) twin-screw extruder - Uncompromising technology and productivity

Since its market launch, the UltraTorque series has been the benchmark for compounding throughput, reliability and product quality. The perfect coordination of machine components, a modular process set-up for optimal product quality, high machine availability, and maximum ease of operation. The result: A state-of-the-art compounding line, which combines reliability and innovation and provides you the decisive competitive advantage in plastics compounding.

ZE-A or ZE-R
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Barrel elements
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Screw elements
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Process control
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Materials & technical specifications
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Applications
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Auxiliary equipment

KraussMaffei Berstorff auxiliary equipment for tapping the full potential of the twin-screw extruder range

Short set-up times, maximum output rates and unparalleled product quality are key factors in successful compounding. To achieve this goal, all components of a compounding line must be perfectly matched.

With twin-screw extruders and appropriate peripheral equipment KraussMaffei Berstorff offers convincing one-stop solutions. All systems are in-house developments or designed in close cooperation with renowned equipment suppliers. Installation and service are performed by KraussMaffei Berstorff specialists.

UltraFeed side feeder vacuum degassing
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Screw preloading system
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ScrewCon
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Compounding plants

Complete compounding solutions from KraussMaffei Berstorff hone your competitive edge with an optimum of all individual components.

The best possible matching of all individual components.

You need expert support in optimizing processes, concepts, logistics, basic and detailed design, and interface coordination for your compounding system? Or you are planning to set up a new extrusion line ?

Then you need a strong partner with the necessary expertise in process technology support, facility design and turnkey solutions. A company that can offer you customized, integrated compounding solutions – from optimized process design, function planning, construction management through the best possible technical coordination of all individual components and operator training up to commissioning. When it comes to design and new construction or modification of a compounding system, we are your reliable partner. We offer you the optimal basis for solutions that are perfectly tailored to your individualized compounding tasks.

System configuration
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Range of services
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Process expertise
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Modular design
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EdelweissCompounding technology

Recycling and compounding in a single step

EdelweissCompounding lines are rated for throughputs of up to 6 t/h. The main benefit of this extrusion solution is the direct conversion of reclaim material into high-quality compounds in a single heat.

 

EdelweissCompounding technology
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Pipe extrusion

The optimal solution for every task in pipe extrusion

KraussMaffei Berstorff offers all machines and systems for manufacturing plastic pipes in the diameter range of 5 to 2500 mm. Double and single-screw extruders and pipe heads are the core piece of each system; aside from that, our product line covers all automation components. To increase cost-effectiveness, we have developed flexible extrusion systems, such as the QuickSwitch system. Aside from that, we offer procedures for reducing material cost. KraussMaffei Berstorff is a system provider for extrusion lines for production of complex special and standard pipes.

Pipe extrusion systems

KraussMaffei Berstorff provides complete systems from a single source as a system solution.

As a system provider, KraussMaffei Berstorff offers all components for manufacturing plastic pipes with a diameter from 5 to 2500 mm, including automation components. Our product line covers single-screw extruders, counter-rotating and co-rotating twin-screw extruders with the corresponding pipe heads, downstream components and peripheral devices, and fully automatic pipelines. All our components and automation systems are consistently designed for the highest degree of material, energy and cost savings with a uniformly high quality of products. For every application, we offer systems tailored to the customer's wishes from a single source.

Double and single-screw extruders are the core of a complete system. Modular construction, with integrated control cabinet and control panel, makes it possible to be used for any customer-specific application. All downstream components such as the vacuum tank, the spray tank, the haul-off, cutting units, socket forming machines and additional equipment are optimally tuned to one another; the automation components are designed for maximum operational safety and ease of operation and servicing. With the complete system, optional pipe winders, supplemental systems such as filling units or extended automation equipment such as bundling or palletizing machines can also be provided. The KraussMaffei Berstorff C6 control system, as one of the most modern control, regulation and monitoring systems in extrusion, has intelligent functions for a central line control system.

PO pipelines
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PVC - pipelines
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IPC technology
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Coex solutions
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As a system provider, KraussMaffei Berstorff delivers integrated complete system concepts for economical large pipe production.

Particularly in emerging markets, demand for large pipes made of plastic is growing more and more. To round out its product portfolio, KraussMaffei Berstorff provides systems for PO large pipe production with a diameter of up to 2,500 mm and a wall thickness of up to 100 mm.

Along with the increase in output, the systems stand out in particular because the weight per meter can be reduced to a minimum. The producer benefits from an enormous potential savings in material costs, whose proportion of total manufacturing costs can be up to 90% for the extrusion of small plastic pipes.

With KraussMaffei Berstorff systems, process technology challenges can be implemented cost-effectively and reliably.

36D single-screw technology
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Spiral distributor system
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QuickSwitch technology

QuickSwitch technology for in-line dimension change without interruption of the production process

System for PO pipe production at the highest level of flexibility and lowest costs

With the flexible QuickSwitch system from KraussMaffei Berstorff, the producer can change the pipe dimension at the touch of a button in mere minutes. The centerpiece of the system is the calibration basket with which the complete system can be set quickly to the desired pipe dimension in just one step. With QuickSwitch systems, a special pipe head is used, which is equipped with moving components in the melt outlet. A modification of the die assembly, which is necessary in conventional systems upon each dimension change, is thus omitted. All necessary downstream components are adapted to the QuickSwitch technology. Aside from that, the QuickSwitch system is equipped with an "All-in-one control system". The QuickSwitch functions, which were previously regulated via a separate control unit, are now integrated in an overriding C6 system control unit. The customer benefits from many advantages, for example, a standard operating philosophy, standard hardware, flexible expandability or simple updates. The only scrap for every dimension change is a short cone pipe. All time and material-intensive work procedures that are needed for a conventional dimension change are omitted. The producers create competitive advantages for themselves through an enormous potential savings with regard to material, personnel, and storage space; they can function significantly more flexibly and fill orders of small lot sizes in a short delivery period.

KraussMaffei Berstorff offers the QuickSwitch system for polyolefin pipe production for the diameter ranges of 25 to 63 mm, 70 to 160 mm, and 250 to 450 mm (optional 63 to 140 mm). Alternative diameter ranges are available upon request. Existing systems can be retrofitted with individual modules incrementally and cost-effectively at any time upon request.

QuickSwitch technology
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Single-screw technology

Whether extrusion or coextrusion
Choose the best solution for every task

The compact design of the small single-screw extruder ensures its problem-free integration as a coextruder in a complete production line.
Depending on the task, the coextruder's control system works either independently, speed-synchronized with the main extruder, or it is integrated seamlessly into the overall machine control system.
Coextruders are used in a wide-ranging spectrum of various applications and special tasks, such as for the extrusion of multi-layer pipes, or for the coextrusion of color strips, bonding agents or thin inner and outer layers, oxygen barrier layers or sealing lips.
In addition, these small models can also be used as stand-alone extruders - with their own switching cabinet and C6 control system - for example for the production of pipes with very small diameters.

36D single-screw extruder
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Small single-screw extruder/coextruder
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KraussMaffei Berstorff provides complete system solutions for special tasks in PO pipe extrusion

Extrusion of peroxide cured PE pipes and plumbing and heating pipes

Pipes made of cured PE or of other plastics such as PE-RT or PP-R feature substantially improved properties compared to pipes made of metallic materials. KraussMaffei Berstorff provides complete systems and special customer-specific solutions for this. Depending on the application, either the KraussMaffei Berstorff single-screw extruders of the 36D series or conical twin-screw extruders are used.

The systems feature the highest production speeds; the finished products have low tolerances for wall thickness and diameter and guarantee minimum excess weight.

Extrusion of temperature-resistant pipes
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The KraussMaffei Berstorff PO pipe head series enables flexible manufacturing of single and multi-layered pipes

Adapted properly for performance to the high output of the KraussMaffei Berstorff single-screw extruders and according to the principle of the spiral distributor, the pipe heads cover a large bandwidth of diameters and wall thicknesses. With 13 pipe head sizes, pipe diameters of 5 mm to 2,500 mm can be manufactured. For the production of multi-layered pipes, KraussMaffei Berstorff also offers the corresponding multi-layer pipe heads and the complete system concept. The distribution is usually done via coaxial spiral distributors . Thin outer layers can alternatively also be applied cost-effectively via radial outer layer adapters.

The pipe heads can be used for a wide variety of various PO materials, and provide critical production technology advantages. In this way, the processor achieves a high production flexibility, prevents local stagnation times and generates an optimum pipe quality with higher production reliability. All models are compactly and modularly built and are easy to mount and clean.

The product line also includes special pipe heads for sheathing tasks as well as for the production of pipes made of PE-X and ABS.

The models for the diameter range from 110 to 2500 mm can also be equipped with the innovative IPC technology (internal pipe cooling system) for shortening the cooling system and reducing costs.

Spiral distributor system
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Multi-layer pipe extrusion
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Systems for PUR-insulated pipes

System solutions from KraussMaffei Berstorff

Due to their excellent insulation properties, PUR-encapsulated pipes are ever more in demand, particularly against the backdrop of the global endeavor to save energy and reduce CO2 emissions. The insulation with polyurethane reduces the thermal conductivity of the overall pipe. The medium to be transported is protected from thermal environmental influences such as heat or cold.

As a system provider, KraussMaffei Berstorff delivers integrated total system concepts for producing PUR-insulated pipes and thereby provides the expertise for producing pipes in an extremely economical process.

A complete production line consists of two subsystems:

1. Conventional extrusion system for producing the medium pipe; the medium pipe (in the diameter range from 20 to 110 mm) can consist of PE (link to PO pipelines 3rd level) or PE-X (link to PE_X 3rd level), PE-RT or PB (link to PE-X 3rd level).


2. System for encapsulating one or two medium pipes with polyurethane and for sheathing with polyethylene.

The diameter of the overall pipe ranges from 75 to 180 mm

All components of the systems are perfectly matched to one another and are controlled and monitored via the central C6 line control system with its intelligent functions.

The advantages for the processor are clear:

  • Continuous and cost-effective production of unlimited pipe lengths with a high degree of automation
  • High production reliability and long production cycles
  • Minimum wear of all system components
  • Perfect finished product quality

Systems for manufacturing C-PVC pipes

KraussMaffei Berstorff provides complete systems as a system solution from a single source

When it comes to plastics production from C-PVC, our many years' worth of experience in extrusion technology is in demand. The machines from KraussMaffei Berstorff are best designed from a process technology standpoint to process all current C-PVC mixtures (with an increased chlorine content of 62-69% and a density of 1.50 to 1.55 g/cm³) optimally.

KraussMaffei Berstorff has also already used the features and systems of their extruder and system technology, which have been tried and tested for years, for C-PVC processing. These include fully chrome-plated screws and adapters and vapor-proof chrome-plated nozzles. The screws are coated in molybdenum and work with a nitrited barrel. Optionally, we also offer tungsten carbide armored screws with bimetal barrel.

Our product line includes seven models with screw diameters from 43 mm to 133 mm for a output range from 35 kg/h to 800 kg/h.

The processor benefits from excellent advantages such as flawless wear resistance, cost-effective production with a high degree of automation, maximum output with a homogeneous melt and uniform melt temperature, and excellent product quality.

Direct extrusion systems reduce raw material costs and increase cost-effectiveness

Addition of various fillers improves the material properties and reduces costs

With the direct extrusion systems from KraussMaffei Berstorff, the material is compounded in just one step and the product is simultaneously extruded. The process of treating the polymer with fillers to prepare a compound granulate is coupled with the extrusion of pipes. (The extrusion of sheets and profiles is also possible using this procedure). In this way, fillers such as barium sulfate can be processed in a one-step process.

Direct extrusion saves a complete process step; the one-step process reduces the manufacturing costs; in addition, the material is processed very gently, since it is heat-treated only once.

The finished product displays improved product properties, such as a substantially greater sound insulation.

Co-rotating twin-screw extruders are used for this technology.

KraussMaffei Berstorff pelletizing systems for rigid and flexible PVC

Pelletize cost-effectively and with high-performance

Economical manufacturing of PVC granulates requires a high degree of expertise. Perfect command of the pelletizing process is just as critical here as expertise in raw materials and formulations.

The twin-screw extruders from KraussMaffei Berstorff offer high throughput rates and excellent product quality by means of their product-specific coordinated process units.

The C6 control system ensures a clearly arranged process control, extensive data acquisition, and synchronized operation of the metering unit, extruder, and pelletizing equipment.

Our product line includes counter-rotating twin-screw extruders for the output range from 450 kg/h to 2200 kg/h with screw diameters from 90 mm to 164 mm.

As a system partner we offer the optimum system concept from metering to the finished product.

Premium quality wear resistance on KraussMaffei Berstorff twin-screw extruders

The plasma-powder deposition welding method for coating the top root-face edges on counter-rotating twin-screw extruders

KraussMaffei Berstorff provides molybdenum-based PTA hardfacing as standard wear protection for the top root-face edges on all parallel and conical twin screws. Optimized welding process parameters such as, for example, the amperage in relation to the screw outer diameter and the customized composition of the flux powder ensure the production of PTA-molybdenum hardfacing that is practically free of cracks with the lowest possible dilution especially in the outer areas of the weld. The machines are therefore ideally protected against partial damage such as localized breakages. The plasma-powder deposition welding method minimizes the naturally occurring adhesive wear with counter-rotating twin-screw extruders and thereby enormously increases the service life of the machines. The system is designed for processing screws in the diameter range from 43 to 184 mm.

KraussMaffei Berstorff is also offering a PTA-produced high-wearing surface coating for all parallel twin-screw extruders with tungsten-carbide reinforcement. Tungsten-carbide coatings are used for heavy adhesive wear, for example, when processing natural fiber-reinforced plastics for decking profiles, or when processing highly filled materials.

Processors benefit from a substantially increased service life for the extruders.

Pipe heads for PVC processing

KraussMaffei Berstorff PVC pipe head series enables flexible and cost-effective production of high-quality PVC pipes
With a total of seven different sizes, the pipe head product line of KraussMaffei Berstorff covers a broad diameter range from 16 mm to 800 mm in PVC pipe production. In combination with the 36D twin-screw extruders, they are optimally designed for processing a wide range of U-PVC recipes. The pipe heads are designed according to the mandrel support principle, since it has proven to be best particularly for processing thermally sensitive materials.
Special models of pipe heads are available for processing C-PVC.
For each pipe head, available reductions offer the option of covering most of the diameter range of the next smallest pipe head. In addition to the higher flexibility, this can also achieve a substantial cost savings, since smaller die assemblies are used.
The model of the RKD 200 twin-strand extrusion head makes use of the full extruder performance in the smaller diameter range from 16 mm to 63 mm for cost-effective production. Another twin-strand concept combines two pipe heads via a distributor block; the two parallel downstream units are designed as single-strand lines; consequently, pipes in the diameter range from 16 mm to 250 mm can be produced.
In our product line we also offer three-layer pipe head models for producing PVC foam core pipes, which are used particularly for depressurized applications.
All pipe heads from KraussMaffei Berstorff offer excellent advantages, such as high production flexibility, fast and easy start-up of production due to easy installation and disassembly; they produce pipes of excellent quality in a broad processing window with high production reliability.

36D twin-screw extruders for economical PVC pipe extrusion

36D long procedural concept for high-performance and flexible production
The parallel twin-screw extruders of the 36D series from KraussMaffei Berstorff are specially designed for PVC processing. A broad product line with modular concept offers economical and high-performance production solutions – adapted to the needs of the customer. A perfectly optimized screw concept provides for very gentle and uniform material processing. Long process units increase the process reliability and offer high production reliability in a broad range of applications. With their HPG screw concept (High Performance Geometry), the models of this series are optimally suited for producing a wide variety of PVC formulations, such as U-PVC, M-PVC, foamed PVC or PVC-O mixes. Additionally, cost-effective materials with high filler content can be processed ideally.
They feature outstanding properties, such as high outputs, excellent melt quality, optimum melt temperature, and an extremely low maintenance effort.
Our product portfolio extends from model KMD 75-36 E/R to KMD 133-36 E/R

Foam core technology
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Extrusion of highly filled pipes
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Profile extrusion

KraussMaffei Berstorff supplies individual machines and complete profile production systems for all profile extrusion applications from a single source.

KraussMaffei Berstorff supplies individual machines and complete profile production systems for all profile extrusion applications from a single source.

KraussMaffei Berstorff: Your solution provider for complete profile extrusion lines

We supply complete profile extrusion systems for all profile extrusion applications from a single source. Whether profiles made of PVC, PE or other materials – and irrespective of the profile type you want to produce – our systems open up every available possibility to you.

Our product line includes conical and parallel twin-screw extruders of the 32D series. These are complemented by coextruders for integrated extrusion systems such as piggyback or tandem designs. We provide our customers with tailor-made solutions for high-performance extrusion, for the flexible requirements of core technology, and for the production of technical profiles or for NFC processing.

Coex solutions
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XS extruder
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More flexibility and cost-effectiveness in profile extrusion with the 32D twin-screw extruder series

Whatever questions you may have concerning profile extrusion, we have the right answers.

The 32D series combines excellent profile quality with peak production flexibility and excellent cost-effectiveness in production. The long process unit of the twin-screw extruder decisively improves the melt homogeneity and significantly expands the processing window. In addition, the series is optimally designed for that which the market of today increasingly expects and demands from production: Flexible profile extrusion for maximum cost-effectiveness.

Your advantages at a glance:

  • Excellent profile quality combined with high production flexibility
  • Improved melt homogeneity thanks to a long process unit
  • Expansion of the processing window thanks to a long process unit
  • Optimum design for high demands: high-performance extrusion for maximum cost-effectiveness

In addition, the 32D twin-screw extruders perfectly combine with very diverse coextrusion solutions.

32D twin-screw extruders
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Flexibility and process stability in profile extrusion with conical extruders from KraussMaffei Berstorff

The twin-screw extruders of the conical series are particularly suitable for the lower profile performance range, as both mono-extruders and coextruders.

Moreover, they offer critical advantages with respect to design and process technology. The short, compact design saves valuable production space; by positioning the screw axes diagonally, there is space for a robust transfer gearbox and a strong back-pressure bearing. This machine design ensures optimum functional capability even during rigorous continuous operation. Due to the relatively small screw diameter, minimum back-pressure forces arise in the metering zone, which contributes to the high service life of the back-pressure bearing. The screw concept has been specially designed for processing PVC and achieves extremely gentle material processing.

Additionally, due to the special molybdenum welding technology, these models are optimally suited for use of recyclates or highly filled materials, since they have an extremely high wear resistance. The coextruder can be supplied with its own C6 control system or a control unit integrated in the main extruder. Other advantages of coextrusion solutions are, in addition to the motorized adjustment, the ease of using and swiveling the metering unit and hopper.

Conical series
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Solutions for processing NFC/WPC

KraussMaffei Berstorff covers the entire value-adding chain with its product portfolio of co-rotating and counter-rotating technology for extrusion of composite materials made of renewable resources. From the selection of appropriate raw materials, to the recipe, material processing, and pelletizing, all the way to the extrusion and production of complete application systems, KraussMaffei Berstorff is a system provider that implements individualized customer wishes.

KraussMaffei Berstorff offers an efficient two-stage process. With our co-rotating twin screw extruder, a granulate based on wood flour and PO or PVC can be compounded, which is extruded to the desired finished product in the following step on the counter-rotating twin-screw extruders.

Co-rotating twin-screw extruder
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Counter-rotating twin-screw extruder
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Technical profiles

High-performance machines and systems for production of technical profiles

KraussMaffei Berstorff supplies systems and machines for producing all kinds of technical profiles such as profile strips, lamp covers, lamellae, and tile edge strips; the finished products are used in the automotive, furniture, electrical, and construction industries.

Single-screw extruders
For the extrusion of technical profiles made of materials such as ABS, PMMA, TPE or POM, KraussMaffei Berstorff offers the following models: KME 30-30 B/C, KME 38-30 B/R, KME 45-30 B/C. KME 45 XS, KME 60 XS single-screw extruders

Twin-screw extruders
The product line of conical twin-screw extruders includes the KMD 43 K/P, KMD 53 K/P and KMD 63 K/P models, which can extrude technical profiles from U-PVC.

Premium quality wear resistance

The plasma-powder deposition welding method for coating the top root-face edges on counter-rotating twin-screw extruders

KraussMaffei Berstorff provides molybdenum-based PTA hardfacing as standard wear protection for the top root-face edges on all parallel and conical twin screws. Optimized welding process parameters such as, for example, the amperage in relation to the screw outer diameter and the customized composition of the flux powder ensure the production of PTA-molybdenum hardfacing that is practically free of cracks with the lowest possible dilution especially in the outer areas of the weld. The machines are therefore ideally protected against partial damage such as localized breakages. The plasma-powder deposition welding method minimizes the naturally occurring adhesive wear with counter-rotating twin-screw extruders and thereby enormously increases the service life of the machines. The system is designed for processing screws in the diameter range from 43 to 184 mm.

KraussMaffei Berstorff is also offering a PTA-produced high-wearing surface coating for all parallel twin-screw extruders with tungsten-carbide reinforcement. Tungsten-carbide coatings are used for heavy adhesive wear, for example, when processing natural fiber-reinforced plastics for decking profiles, or when processing highly filled materials.

Processors benefit from a substantially increased service life for the extruders.

Rigid sheet extrusion lines

Through customized extrusion technology for production of premium quality plastic sheets

Sheets of PVC, PO or C-PVC are a contemporary alternative to wood, sheets of fiber, and other compact materials. They can be further processed in many ways, refined, and are used in many areas of the construction and advertising industries. KraussMaffei Berstorff, as a highly skilled system provider, for years has offered proven, integrated total system concepts for a variety of films and sheet products. The advanced application and process knowledge of our application engineers and getting all engineering work from a single source reduces your effort upon start of production and in the rest of the production process.

PVC sheet extrusion

As a system provider, KraussMaffei Berstorff offers proven, integrated total system concepts for a variety of films and sheet products made from PVC

Our 32D technology has long been proven in profile extrusion, and is also used in PVC sheet production. While the KMD 164-32/PL provides for high output with foam sheets, the KMD 114-32/PL and KMD 133-32/PL models have proven excellent for the production of thermoformable compact sheets and for foam sheets. These two machine models are best suited for common product applications.

In order to be able to produce the high-quality foam sheets, an enormous amount of experience in extrusion technology is necessary. Moreover, in-depth expertise is required. The dies and downstream units also influence the extrusion process critically. The advanced application and process knowledge of our application engineers and getting all engineering work from a single source reduces your effort upon start of production and in the rest of the production process. Aside from that, we offer a series of coextrusion models, which open up many possibilities to you to develop new production properties and enter new markets.

Complete systems
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32D twin-screw extruders
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26D twin-screw extruders for coex
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Wear resistance
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C-PVC sheet extrusion

KraussMaffei Berstorff provides complete systems as a system solution from a single source

If something involves production of C-PVC sheets, our many years of experience in extrusion technology is in demand. The machines from KraussMaffei Berstorff are best designed from a process technology standpoint to process all current C-PVC mixtures (with an increased chlorine content of 62-69% and a density of 1.50 to 1.55 g/cm³) optimally.

KraussMaffei Berstorff has also already used the features and systems of their extruder and system technology, which have been tried and tested for years, for C-PVC processing. These include fully chrome-plated screws and adapters and vapor-proof chrome-plated dies. The screws are coated in molybdenum and work with a nitrited barrel. Optionally, we also offer tungsten carbide armored screws with bimetal barrel.

For sheet extrusion, you can select between three models with outputs up to 800 kg/h.

The processor benefits from excellent advantages such as flawless wear resistance, cost-effective production with a high degree of automation, maximum output with a homogeneous melt and uniform melt temperature, and excellent product quality.

PO sheet extrusion

KraussMaffei Berstorff is a system provider for integrated, complete solutions for a wide variety of sheet products in PO processing

The importance of polyolefin-based plastics has grown continuously for decades, and the trend is rising. They are used ever more frequently, above all in the sheet extrusion area. The 36D single-screw extruders from KraussMaffei Berstorff are optimally suited for extrusion of compact or foamed sheets made of polyolefins.

We provide you with everything you need for successful production: integrated, total system concepts for a wide variety of sheet products in PO processing. We also provide you with advanced process and application experience and comprehensive technical expertise as a system provider.

Complete Systems
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36D single-screw extruders
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PS/ABS plastic sheets

Efficient across all dimensions.

KraussMaffei Berstorff has developed sheet extrusion systems specifically for manufacturing high-quality plastic sheets for a wide variety of products. For example, cost-effective components for devices or facade cladding are produced using a hot deformation process.

Optical elements for screens or vehicles continue to be innovative applications. KraussMaffei Berstorff fulfills these diverse product requirements and conditions from a process technology standpoint by means of absolute customer-specific flexibility in planning a system and designing its extruder concept. Well-founded knowledge of the extrusion and polishing processes as well as the availability of calculation bases in every detail make KraussMaffei Berstorff a reliable partner for extruding sheets with the best respective extruder concept.

Unrivaled productivity and flexibility.

Optimized single-screw extruders and high-performance twin-screw extruders can be operated as part of sheet extrusion in the mono- as well as coextrusion processes. The subsequent polishing process can be implemented by choosing either stationary rolls or the extremely flexible PlanetCalander®. Sheet quality and cooling capacity can be optimally configured.

The sheet extrusion systems configured in this way feature peak dimensional accuracy of the sheets with high extrusion performance. Additional features of the systems include freely selectable sheet path and high productivity for sheets with up to 80% filler and reinforcement materials as well as thicknesses up to 65 mm, widths up to 4 m, and throughputs up to 3,000 kg/h.

Single-screw extruders
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Polishing stack technology
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Down-stream Equipment
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PC/PMMA/SAN/PET-G plastic sheets

Sheet extrusion systems with clear results

Quality and purity play a large role in manufacturing transparent sheets. Therefore optimally coordinated machine technology has to be used for manufacturing sheets requiring high transparency, scratch and impact resistance, UV resistance, and good thermoforming properties.

Innovative ideas join up with advanced technology to create a maximum of efficiency and reliability. KraussMaffei Berstorff sheet extrusion systems form a unique, one-of-a-kind performance class for the highest quality and productivity requirements in manufacturing clear plastic sheets. From extruding the plastic recipe to stacking the finished sheets, the systems fulfill all requirements for perfect operability and the shortest setup times in the case of product change and high machine availability. KraussMaffei Berstorff fulfills the diverse product requirements and conditions from a process technology standpoint by means of absolute customer-specific flexibility in planning a system and designing its extruder concept. Well-founded knowledge about the complete production process makes KraussMaffei Berstorff a reliable partner for manufacturing clear sheets.

36D Single-screw extruders
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Polishing stack technology
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Down-stream Equipment
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Flexible sheet extrusion lines

Economical manufacturing of premium quality plastic sheets has never been so easy.

Even easier — KraussMaffei Berstorff, as a general contractor, provides all services for constructing a high-performance extrusion system, beginning with the system logistics and design, then the actual construction of the system, and then training and production support for all services.

Even more economical — process and shape plastic recipes in a single pass with a twin-screw extruder, achieve higher throughputs by using cost-effective raw materials. The reincorporation of edge strips and scrap webs increases the cost-effectiveness even more.

Even higher quality — together with its reliable single and twin-screw extruders and the polishing stacks that are perfectly tailored to the requirements, the KraussMaffei Berstorff systems provide optimum prerequisites for producing premium quality plastic sheets.

Standard thermoforming sheet lines

Easy implementation, compact shape, and fast amortization

Extrusion with single-screw extruders and specified modules.

You will immediately see the cost-effectiveness of the KraussMaffei Berstorff standard thermoforming sheet lines. The 4 modules of the system are consistently designed and technically coordinated according to the modular principle.

Commissioning within a short time.

The compact design and the function check at the factory enable the system to be quickly commissioned. In no time you will realize how easy it is for your standard thermoforming sheet lines production to be increased or updated. And the following applies for coextrusion tasks: With a second extruder that is simply connected to the coextrusion adapter, you can produce multi-layered sheet without high expenses.

KraussMaffei Berstorff standard thermoforming sheet lines are available in 3 sizes for throughputs from 550 kg/h to 1,500 kg/h and for foil widths from 400 to 2,000 mm.

Typical materials: PS, PP, PET

Typical products: glasses, bowls, plates, blisters, etc.

Extrusion technology
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Polishing stack technology
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Down-stream Equipment
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High-quality thermoforming sheets

Optimizes systems with customer-specific equipment

KraussMaffei Berstorff high-quality thermoforming sheets systems for in-line compounding of thermoformable sheets enable not only the perfectly efficient production of premium quality sheets for a wide variety of packaging tasks. The twin-screw extruders of this system also combine in a continuous process the otherwise separate process steps of compounding and sheet extrusion. Moreover, the system has additional advantages for your production:

  • Cost advantages through processing of raw materials (granulates, beads, powders, shavings) instead of precompounded granulates
  • Lower capital lock-up for materials
  • More flexible changeover of recipes
  • 100% reincorporation of regrind (edge strips, startup material, scrap webs)
  • Improved melt quality of the raw materials
  • Compact design with correspondingly low space requirements

Maximum performance across the board

The special strength of this system is in manufacturing sheets with up to 70% filler and reinforcement materials with thicknesses between 150 and 2,000 μm.

Typical products include margarine and yogurt containers, coffee cups, flowerpots, molded car parts.

Typical materials:

LDPE, HDPE, PP, PS, ABS

Twin-screw extruders
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Polishing stack technology
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Down-stream Equipment
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Technical sheet

The customized system solution for every product and procedure

Systems for producing technical sheet are designed by KraussMaffei Berstorff to match the needs of particular customers and procedures. They enable manufacturing of a wide variety of sheet, such as for the automotive and automotive supplier industry, for building construction and underground construction, and for a large number of applications in the area of design engineering.

The KraussMaffei Berstorff twin-screw extruders of these systems are designed so that they adapt themselves to the specific requirements of your products and procedures as if made-to-measure. They combine compounding and sheet extrusion in one continuous process.

Optimized polishing stack designs are available for this, depending on requirements from a process technology standpoint and product-specific requirements. When using the PlanetCalander®, the positioning of the polishing rolls can be continuously adjusted in a very broad range.

Coordinated with precision: complete, efficient, and from a single source

The systems for technical sheet are suited for manufacturing with up to 80% filler and reinforcement materials; the range of thicknesses is between 150 and 3,000 μm.

Typical materials:

LDPE, HDPE, PP, W-PVC, PS, ABS, PC, PMMA, TPO, TPU, PVB, EVA

Typical products:

Automotive sheets for the vehicle interior, instrument panels and door inner panels, sheets for solar panels, decorative sheets for furniture, very diverse sheets for underground construction.

Twin-screw extruders
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Polishing stack technology
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Down-stream Equipment
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Fabric-reinforced sheets

Economical systems for complete single or double-sided coating—even with in-line compounding.

KraussMaffei Berstorff extrusion coating systems always provide an optimal economical solution for your sheet manufacturing. The systems prove themselves in daily use in the manufacturing of various fabric-reinforced webs, which are used for a wide range of applications in construction. The wide range of extruder and calender products makes them the ideal choice for every requirement. Pioneering technologies from the proven KraussMaffei Berstoff range of sheet systems, such as modularly designed twin-screw extruders and 5 different polishing stack models, ensure reliability and maximum sheet quality. Coatings are feasible with up to 80% filler and reinforcement materials and thickness between 250 and 3,000 μm, foil width of up to 3,600 mm and throughput up to 4.5 t/h.

Layer for layer, perfect.

KraussMaffei Berstorff systems integrate all process steps, from the supply of raw materials through the extrusion of the various recipes for front and rear side, the coating procedures, embossing, and cooling to the edge stripe processing and development on large or short web rolls in a single process.

Typical materials:

LDPE, HDPE, PP, W-PVC, TPO, TPU

Typical products:

Roofing membranes, sheet for swimming pools and ponds, for sealing rainwater collecting basins and landfills, for ground coverings and floor coverings.

 

Twin-screw extruder
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Polishing stack technology
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Down-stream Equipment
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Foam extrusion lines

Highest product quality and reliability

KraussMaffei Berstorff provides reliable and high-performance machines and systems along the entire value-adding chain for manufacturing physically foamed boards, pipes, and sheets made of plastic. They meet all of the requirements for an efficient extrusion process.

The advantages at a glance

  • Output from up to 2,800 kg/h in manufacturing XPS boards
  • Broad processing spectrum of all standard plastics (PS, PE, or PP) and many high-temperature plastics (PET, PEI, and PES) up to a maximum temperature of 350°C
  • Processing environmentally friendly propellants
  • Reusing startup material, edge strips, and scrap webs
  • Central system control with touchscreen for consistently intuitive and ergonomic operation
  • Perfectly coordinated system components
  • Optimally equipped TechCenter for product development and process optimization

Foam board systems

ISO-Board Schaumtandex systems — reliable, economical, and proven in the manufacturing of XPS boards

The ISO-Board Schaumtandex systems are the world's most successful systems for manufacturing XPS heat insulation boards. Amazing? Not really. KraussMaffei Berstorff knows the stringent requirements that a Schaumtandex system has to fulfill to make a successful contribution — both today and in the future.

IsoBoard Schaumtandex systems are the leading technology for increasing productivity and efficiency in the manufacturing of XPS boards. In addition to the designing the extruders from a process technology standpoint, what is most critical here is coordinating the various system components. Outstanding quality is in demand here, as well as absolute reliability and resistance.

We deliver everything from a single source from solving the process problem to designing and manufacturing the systems — everything from a single source, and thereby we provide our customers with a high degree of confidence. With a background of comprehensive expertise and well-founded experience, we provide the necessary expertise, technical skills, reliability, and innovation which is required for success in sheet manufacturing.

KraussMaffei Berstorff develops all components — ranging from raw material handling, metering of individual components, extrusion technology, and sheet processing all the way to the packaging and storage of the sheets — or designs them in close cooperation with renowned suppliers.

All Iso-Board foam tandex systems are designed for processing environmentally friendly propellants. Board widths from 600 mm to 1,200 mm can be realized with the various systems.

Schaumtandex ZE/KE
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Schaumtandex KE/KE
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Tube and profile systems

Innovation and resistance combined perfectly.

The ISO-TUBE Schaumex and Schaumtandex foam extrusion systems meet the highest demands with regard to quality, productivity, and reliability in the manufacturing of PE, PP, PE/EVA foam pipes or profiles. Whether as a:

  • Schaumex system with a single-screw extruder for small throughputs
  • Schaumtandex KE/KE with 2 single-screw extruders for medium throughputs
  • Schaumtandex system ZE/KE with a twin-screw extruder and a single-screw extruder for highest throughputs.

KraussMaffei Berstorff has networked heterogeneous process steps such as metering, melting the plastic recipe, mixing the propellant, foaming, cutting, or stacking into automatically controlled systems. The system concept has a customized solution for all operation-specific requirements.

Schaumex
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Schaumtandex ZE/KE
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Schaumtandex KE/KE
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Downstream equipment
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Sheet systems

Excellent sheet quality, high throughputs, and reliable machine technology.

The KraussMaffei Berstorff Schaumex and Schaumtandex foam extrusion systems combine decades of procedural expertise and innovative technology for innovative extrusion concepts. The systems provide excellent product properties precisely for sheets made of polystyrene, polyethylene low-density foam, and polyethylene or polypropylene high-density foam.

Depending on the original material and process, the sheets can have totally different properties. Here in particular, the finely incremented temperature control in our extruders guarantees a high quality standard.

Schaumex® and Schaumtandex systems produce the right sheet for every task:

  • In the packaging industry, for foodstuffs and electrical devices
  • In the building materials industry, for impact sound insulation
  • For technical articles such as seals, edge protectors, or cover gaskets
  • In the automotive industry, for example, for roofliners, seals, impact protection, rear shelves, and front door panels and for many other fields of application

 

Schaumex
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Schaumtandex ZE/KE
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Schaumtandex KE/KE
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Downstream equipment
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PVC-Pelletizing systems

KraussMaffei Berstorff pelletizing systems for rigid and flexible PVC

Pelletize cost-effectively and with high-performance
Economical manufacturing of PVC granulates requires a high degree of expertise. Perfect command of the pelletizing process is just as critical here as expertise in raw materials and formulations.
The twin-screw extruders from KraussMaffei Berstorff offer high throughput rates and excellent product quality by means of their product-specific coordinated process units.
The C6 control system ensures a clearly arranged process control, extensive data acquisition, and synchronized operation of the metering unit, extruder, and pelletizing equipment.
Our product line includes counter-rotating twin-screw extruders for the output range from 450 kg/h to 2200 kg/h with screw diameters from 90 mm to 164 mm.
As a system partner we offer the optimum system concept from metering to the finished product.

Spitzenergebnisse in der Granulierung – mit den parallelen Doppelschneckenextrudern der 32D Baureihe

Das Schneckenkonzept der 32D Doppelschneckenextruder-Baureihe optimiert die Materialaufbereitung, verbessert die Schmelzehomogenität und bietet ein sehr breites Verarbeitungsfenster unterschiedlichster Materialien.

Ihre Vorteile:

  • Optimierte Luftanströmung im Granulator
  • Kein Verkleben von Granulatkörnern
  • Geschlossenes Kühlluftsystem mit Staubabscheidung
  • Einfache Bedienung
  • Steuerung vom zentralen Extruder-Bedienpult
  • Schnelle und bequeme Reinigung
Parallele Doppelschneckenextruder der 32D-Baureihe
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Laboratory extruder

The lab operation places special demands on an extrusion line precisely in terms of size and performance. We offer the right concept for all laboratory applications.

Laboratory extruder for pipes / profile / sheets / pelletizing

KraussMaffei Berstorff supplies the laboratory model for all applications, such as quality control, pipe, profile and plate extrusion and for granulation - both as a single machine and as an overall concept. With our systems you have all the possibilities.

The laboratory extruder is small and compact. It is specially designed for the processing of U-PVC and soft PVC recipes of all kinds - in all common forms such as dryblend, granulate or recycled.

Your benefits

  • High process reliability
  • Significant reduction in material costs
  • Wide processing window for versatile recipes
  • Excellent product quality
  • Low maintenance costs

Laboratory and pilot lines

The Schaumtandex lines are an excellent and unique machine combination for research institutes and R&D centers.

Designed for low output rates, the Schaumtandex line is suited for processing all standard plastics and a wide range of high-temperature plastics up to a maximum temperature of 350°C. The eco-friendly blowing agent is injected in liquid form through appropriate nozzles into the processing section of the twin-screw extruder and subsequently mixed in. Thanks to the extensive screw and barrel portfolio, the extruder can be retrofitted for new process applications at any time.

Various laboratory line configurations

Compounding extruders can be equipped with cooling extruders or static coolers designed for melt cooling. – ZE 25 compounding extruder with static cooler – ZE 30 compounding extruder with static cooler or with KE 60 cooling extruder – ZE 40 compounding extruder with static cooler or with KE 90 cooling extruder.

Your benefits:

  • Processing of all standard plastics
  • Extensive screw and barrel portfolio
  • Cooling extruder with “active melt seal”