Coperion at K 2025: Technologies for Greater Compounding Efficiency

Stuttgart, July 2025 – Increasing efficiency is the key to economical and sustainable success in plastics processing. Appropriate to the occasion, Coperion will present new products and developments for various process steps that contribute to increases in both compound quality and machine efficiency. Moreover, they further advance responsible use of resources. Along with compounding, technologies for plastics recycling constitute a Coperion core competency. Together with Herbold Meckesheim, Coperion will display this expertise at the open area Pavilion FGCE07 as well as in Hall 9 at Booth 9B34. 

Smart solutions for compounding tasks

From individual key components through to complete compounding lines, Coperion realizes solutions for manufacturing engineering plastics, masterbatches, bioplastics, LFT, PVC, HFFR, TPE and many other plastics. To accomplish this successfully, Coperion draws upon its comprehensive expertise in all process steps for bulk material handling, conveying, feeding, compounding and after-sales service. In all decisions concerning scope of delivery, depth of services, and process chain optimization, support from a single source offers compounders numerous advantages. There is only one point of contact and one supplier – from machine concept and engineering to commissioning. Every key component embodies Coperion’s manufacturing and process engineering expertise. Material handling components include rotary and diverter valves, heat exchangers and separators. Compounding equipment includes ZSK and STS twin screw extruders and feeding solutions include a wide range of options from Coperion K-Tron and former Schenck Process FPM. Coperion ensures seamless connection of every process step for compounding. Moreover, Coperion lines can be operated with a high degree of automation as needed.

At K 2025, Coperion will display its competence in realizing entire plants with the aid of an all-encompassing 3D simulation. Visitors to Booth 14B19 will glean detailed insights into how an entire line functions as well as into the workings of individual components.

Along with compounding machinery, Coperion realizes entire systems for polyolefin manufacturing. At K, the company will present the new DewTector, an online measuring device that reliably measures the residual moisture content of polyolefin granulates or engineering plastics in the running system.

Highest compounding efficiency – ZSK Mc¹⁸ and STS Mc¹¹ high-performance extruders 

Coperion is a pioneer in the development of closely intermeshing, co-rotating twin screw extruders. At Booth 14B19 in Hall 14, Coperion will display two representatives of its high-performance extruder offerings: a ZSK 58 Mc¹⁸ and an STS 35 Mc¹¹.

The ZSK 58 Mc¹⁸, with a screw diameter of 58 mm, has a specific torque of 18 Nm/cm³. It achieves throughputs of up to 2,500 kg/h with low energy consumption. ZSK extruders have proven themselves over many years with their high dispersion performance and gentle product handling, ensuring very high product quality. The extruder is robust and reliable and its operational availability as well as its OEE (Overall Equipment Effectiveness) value are extremely high. Newly developed screw elements reduce abrasion in the melt zone to a minimum while achieving very high throughput increases in processing fillers.

The STS 35 Mc¹¹ stands out with exceptional efficiency and an attractive price-to-performance ratio. It is especially well suited for manufacturing high-quality masterbatches. With its maximum specific torque of 11.3 Nm/cm³ it achieves throughputs of up to 300 kg/h. The closely intermeshing twin screws provide very good dispersion of ingredients and optimal self-cleaning in the process section. The extruder is compactly designed and easy to clean, thanks to its smooth surfaces.

New benchmarks in feeding technology

Feeding technology is one of Coperion’s core competencies. With its myriad feeding technologies, the company offers a broad palette of solutions that are all exceptional for high feeding accuracy and easy handling.

Representative of its variety of products, Coperion will display the high-accuracy Coperion K-Tron K2-ML-D5-T35 twin screw feeder equipped with EPC (Electronic Pressure Compensation) and the ActiFlow™ bulk solid activator. Likewise, the preconfigured ProRate PLUS-MT feeder will be available to view. Both of these gravimetric twin screw feeders are ideal for feeding free-flowing and more challenging bulk materials. 

Only recently available from Coperion, the volumetric AccuRate® 602 single screw feeder as well as the gravimetric MechaTron® Coni-Flex model will be on display. The latter has been developed especially for applications with frequent material changes and several cleaning cycles. 

In the future, the feeder lines previously known as Schenck Process FPM will be integrated into the Coperion SmartConnex feeder control environment. This system offers comprehensive control and monitoring functionality for feeding equipment as well as a maximum of flexibility and available connections. At K 2025, visitors to the Coperion booth can get a first impression. 

Comprehensive services for maximum equipment availability

Coperion aims to ensure high performance availability throughout the entire life cycle of its technologies, to minimize downtime risk, and to consistently uphold the efficiency of processes. A global network of highly specialized process and development engineers allows Coperion to service lines and machinery in use, undertaking service measures on short notice with the benefit of accumulating prior knowledge of local circumstances. Using individually tailored service agreements, Coperion assumes responsibility for regularly scheduled inspections, maintenance, and further preventive service measures. Forward-looking and structured planning of service measures keeps inspection and maintenance times as short as possible and drastically reduces potential damage risks. 

Using a condition monitoring system, operation of ZSK twin screw extruders from series ZSK 40 up to ZSK 140 can now be permanently monitored. The keys to this system are sensors on the motor, gearbox and process section that monitor the extruder’s operation. Data is captured continuously and is available in real time. Within the framework of a service agreement, Coperion experts access the measurement results remotely, issue relevant reports, and form conclusions regarding necessary service measures. These can then be planned and carried out with full consideration of operational needs, ensuring that a ZSK extruder’s high productivity is impacted as little as possible.