LEISTRITZ EXTRUSIONSTECHNIK GMBH

Z S E

M A X X

refreshing
e x t r u s i o n
technology

A Great Team - the Basis for Success

Leistritz Extrusionstechnik GmbH has established itself
as one of the leading manufacturers of co-rotating twin
screw extruders. This is facilitated by the latest technology and especially by the 150 employees worldwide - a
team which stands behind its product.
For more than 50 years, the company has been building and optimizing twin screw extruders for the plastics technology as well as the pharmaceutical and food
industries. Nrnberg plays an important role as headquarters. The heart of the extruder - the screws and
barrels - are exclusively manufactured by Leistritz. Thus,
constant high quality is guaranteed. This is mainly possible by the symbiosis of the various Leistritz product
groups in terms of superior in-house metal machining
technology, e.g. whirling and ECM (electro chemical
machining).

A team which lives XX ...

C O M PA N Y

In order to provide state-of-the-art turnkey extrusion

systems, the overall concept and the logistics have to
be right. A process flow based on the ISO 9001:2008
certification guarantees optimized procedures and fast
communication channels. Long lasting partnerships
with distributors and customers provide a trustworthy and professional cooperation for complex requirements.
Leistritz customers benefit from a profound experience:
The company plans, designs and produces individual
extruders and turnkey extrusion lines for a wide variety
of processes and applications.

Torque AND Volume

Leistritz has established itself as the leading manufacturer for twin screw extruders worldwide. The only possible way to survive in this highly competitive market is
by the continuous quest for innovation and by being
receptive to the customers needs. True to the motto
refreshing extrusion technology the ZSE MAXX series offers an innovative machine concept with partly
revolutionary improvements which hitherto have been
unique in the market:
A special combination of high torque and high
volume in ONE extruder.

The extruder user experiences a whole new degree of

freedom: In the focus of the ZSE MAXX series is the increase of productivity, throughput and quality. In addition to that a significant expansion of the process window applies. All these are arguments that convinced
the experts.
This product range opens the world of productivity via
flexible technology. For production it means: more efficiency for securing the future.
As usual, the evidence is given in practical applications:
This is why in our very well-equipped lab the machines
are ready for trials.

Torque

High volume combined with a

very high specific torque
Torque increase for splined shafts
according to DIN standard

2007

+36%

2004

+20%

Only possible with

the new shaft design:
maXXshaft

ZSE MAXX Series

+30%

ZSE HP Series
1995
+30%

2004

+30%
+40%

ZSE GL Series
< 1990

ZSE HPV
2001

Volume

TECHNOLOGY

Advantages of the ZSE MAXX Series

ZSE MAXX - one machine for torque

AND volume limited formulations

Now the poker game has an end

The ingenious combination of torque and volume in
one machine is highly relevant in terms of process
technology. A wide range of processes profits from the
maximum adaptability of the ZSE MAXX. In the past,
processors had to choose between a high volume and
a high torque machine. Especially, against the background of the constantly faster market development
they were confronted with a significant investment risk.

TECHNOLOGY

Advantages of the ZSE MAXX Series

The ZSE MAXX Series offers maximum values for torque
and volume in one system (OD/ID = 1.66).

With this gear-generation for the whole MAXX series

the torque has been increased very high. This is why
this feature is rightly called maXXtorque. The specific
torque of this series is:

By an optimized volume/torque ratio the throughputs

increase significantly by up to 50 %. This is made
possible by a splined shaft design - maXXshaft - that
opens up new potentials.

15.0 Nm/cm3
Due to the increased throughput/energy ratio, the cooling capacity also had to be increased. With maXXcooling up to 30% more cooling capacity is achieved
by a sophisticated flow of cooling agent.

The design allows for deeper screw channels at highest

torques so that the free volume in the processing unit is
increased by up to 30%. Consequently, maXXvolume
is available for volume-restricted processes. Ratio of
outer screw diameter to inner screw diameter:

The modular barrel and screw system can be fully

utilized due to a flexible machine design.

OD/ID = 1.66

50% increase of throughput by means of:

maXXvolume
Increased free volume in the screw (OD/ID = 1.66)

maXXshaft
Very high total torque by new splined shaft design

maXXcooling
Up to 30% increased barrel cooling capacity by means of
optimized flow of the liquid coolant through the barrel
cooling bores

maXXtorque
Very high available specific torque with co-rotating twin
screw extruders (up to 15.0 Nm/cm3)

Increased screw volume at the

same centreline distance like the
ZSE HP series
(orange = increase in volume)

Shaft profile with significant

potential for the future

Optimized barrel cooling system

with maintenance-free high-end
valves

Extremely reliable and powerful

co-rotating extruder gear box

TECHNOLOGY

maXXvolume
30% increase of throughput by means of increased volume
When running volume restricted processes, i.e. dryblends, pigment preparations, fillers or additive concentrates, the increased volume of the ZSE
MAXX series has significant effect. The increased volume of up to 30% is
realized with lower cut screw flights and larger external diameters.

Visualized:
Difference in volume of a ZSE 50 HP
in comparison to a ZSE 50 MAXX

With an OD/ID of 1.66 Leistritz found the optimum ratio

between high volume and energy input into the product. The shear effect is slightly smaller than of the ZSE
HP machines. Nevertheless, it facilitates excellent dispersion. At the same time, high throughputs of many
formulations with constant or even better quality can
be achieved.

centre line
distance

The geometry of screw elements in twin screw extruders are calculated by means of the so-called Erdmenger profile. Hence, the elements are subject to exactly defined geometrical specifications. The ZSE MAXX
machines offer the best balance between deeper screw
channels and technically sensible flight tips (see on the
right).
The optimum in terms of process and material lies in
the range between 1.5 and 1.66. The OD/ID ratio above
1.66 is critical, since it poses two problems:
1. The wear of thin screw flights is very high due
to physical limits.
2. The handling of the screw elements with re spectively thin screw flights becomes more and
more difficult, since the screw flights become
extremely sharp.

Z S E M A X X F E AT U R E S

OD/ID
1.8

1.66

1.5

Critical sector
for wear and
handling

maXXcooling
30% more cooling capacity for an expansion of the process window
ZSE MAXX extruders facilitate an increase in throughput of up to 50%. That implies: The energy balance
in the processing unit is changed. Consequently, the
cooling capacity partially has to be increased. Leistritz
meets this claim with maXXcooling:
By doubling the in- and outlet in each barrel and by
using a sophisticated cooling bore system, significantly
more cooling agent can flow through the barrel. The

cooling capacity can be utilized ideally, because of

the small distance between the cooling bores and the
processing chamber as well as the counter flow principle.
The processing unit is mounted on a functional carrier
system with an integrated cooling pipe installation. The
high-quality coax valves are assembled in the frames
in a very space saving way.

Advantages of the
coax valves:
long durability
short closing speed
compact construction
maintenance-free
backward pressure safe
work from
0 bar upwards

Z S E M A X X F E AT U R E S

maXXshaft
For a long time, the standard involuted spline connection according to DIN 5480 had been first choice for screw
elements and shafts. However, when transmitting extremely high torques the DIN 5480 spline profile meets its
physical boundaries for thin-walled hubs. Thus, it was necessary to reconsider using the spline profile in order to
further develop co-rotating twin screws. The result - maXXshaft - is amazing as well as simple: Since the power
transmission in a co-rotating twin screw just needs to be carried out in one direction of rotation, the spline profile
is changed to an asymmetric shape.
FM

Ft

Fr

hub

hub
Ft

a
a

a=0
shaft

shaft

DIN 5480

maXXshaft

a = 30

Ft = cos a . FM
Fr = sin a . FM

When transmitting torque, a radial tension evolves,

which puts additional stress on the screw element.
This means that the screw flights cannot be cut very
low as otherwise the screw element would burst.

a = 0

Ft = FM
Fr = 0

No additional radial tension arises, i.e. screw flights can

be cut lower and - benefiting from the optimized shape
stability - torque can even be increased.

When using an asymmetric spline profile, more splines can be placed around the shaft, i.e. the transmittable
torque is higher than for a symmetric spline profile.
The handling of the maXXshaft connection is as easy as for the conventional involuted spline profile. Assembling
the elements works perfectly. So the setup time of a ZSE HP and a ZSE MAXX are comparable.
Due to the asymmetric spline profile, the assembling position of the elements is given. Thus, no more mix-ups can
occur. Especially for nonstandard elements, this is a particularly important aspect.
Consequently, reversed assembling of worn elements is not possible any more and protects the extruder from
damages.

With elaborate 3D calculations and long-term stress testing, the new hub/shaft
connection was checked thoroughly by independent institutes. The outcome:
The new hub/shaft connection transmits maximum torque.

Z S E M A X X F E AT U R E S

maXXtorque
The gearbox is an important factor when talking about
the availability of a twin screw extruder. The transmission gear with dual power distribution is a master
piece of the German art of engineering. The extremely
high-power density was reached by high-quality work-

manship, constant research and longterm know-how.

It meets the extremely high Leistritz standards and
convinces by maximum torque density at comfortable
safety factors.

The advantages at a glance:

thick-walled housing
noise optimized by means
of specially finished gears
efficiency optimized
lubrication system

maXXtorque gearbox
in a section perspective

A sophisticated oil system ensures the best possible

lubrication of all shafts and gears. With heavy duty oils,
the lifetime of gearboxes is optimized and maintenance
intervals maximized.
maXXtorque stands for an extremely powerful drive
concept for co-rotating twin screws.

Z S E M A X X F E AT U R E S

ZSE MAXX Details

The whole machine concept is based on a platform construction. This facilitates a wide range of modules and a
stronger extruder systemization. A further advantage: This way, the length of the processing unit can be changed
quite easily. By this, the user gets a higher investment security.
3
1
2

4
5

maXXtorque gearboxes with the same centreline

distance as the HP series

quick-release adapter for side feeder

extruder can be operated from four sides

(left/right, front/back)

water-cooled drive

safety clutch

7
6

control cabinet system, placed directly

at the machine (electricity supplies for drive,
control and heating/cooling system)

oil system for gear lubrication

Especially for masterbatch production,

Leistritz offers the following extruder
design with optional features:
1

barrel support frame with integrated water in- and outlet

supplies for auxiliary equipment integrated in a central supply

water-cooled cover

10 D E S I G N

1
2

The System for maXXimum Options

Sp
(N ec.
m to
/c ta
m3 lt
) s orq
m
ta ue
aX
nd
(N X
ar
m tor
d
/c qu
m3 e
)

Sc
O rew
D
(m Dia
m m
) et
er
O
D/
ID

Ty
p

The ZSE MAXX Series takes twin screw extrusion to a new dimension.

18

18.5 1.66 11.0 -

27

28.3

1.66

11.0

12.5

40

41.4

1.66

11.0

15.0

50

51.0

1.66

11.0

15.0

60

61.6

1.66

11.0

15.0

75

77.0

1.66

11.0

15.0

87

89.4

1.66

11.0

15.0

110

113.1

1.66

11.0

15.0

135

138.7

1.66

15.0

160

158.9

1.66

15.0

180

178.8

1.66

15.0

Z S E M A X X S E R I E S 11

LEISTRITZ GROUP
LEISTRITZ
TURBOMASCHINEN TECHNIK GMBH
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Extruders and Extrusion Lines
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PRODUKTIONSTECHNIK GMBH
Tubing Technology/Sheet Metal Forming,
Machine Tools, Tools

Partner for
Modern Technology

LEISTRITZ EXTRUSIONSTECHNIK GMBH

Markgrafenstr. 29-39 . D-90459 Nrnberg

LEISTRITZ Machinery (Taicang) Co., Ltd.

Shanghai Branch

Leistritz Advanced
Technologies Corp. . BU Extrusion

Phone +49 (0) 911 / 43 06 - 240

Fax
+49 (0) 911 / 43 06 - 400
eMail [email protected]

Phone +86 21 6352 3268

Fax
+86 21 6352 3138
eMail [email protected]

Phone +1 908 685 2333

Fax
+1 908 685 0247
eMail [email protected]

LEISTRITZ France Extrusion

LEISTRITZ Italia Estrusione

Phone +33 (474) 250 893

Fax
+33 (474) 250 864
eMail [email protected]

Phone +39 0331 500 956

Fax
+39 0331 482 586
eMail [email protected]

LEISTRITZ SEA Pte Ltd.

Singapore office
Phone +65 6569 3395
Fax
+65 6569 3396
eMail [email protected]

refreshing extrusion technology

XX_V_11_GB / 18.12.14

www.leistritz.com