EXTRUSION TECHNOLOGY
Twin screw extruders and systems
↗ Overview ↗ Overview
XXPERIENCE COUNTS! TWIN SCREW EXTRUDER DESIGN
Leistritz Extrusion Technology Modular barrel and screw system
Established in 1905, Leistritz is a multi-national compa- the plastics and pharmaceutical industries all around the Co-rotating, intermeshing twin screw extruders (TSEs) matched to the process and can be highly corrosive and
ny with business units in a number of high technolo- world. Whether your requirement is a laboratory sample continuously mix plastics formulations consisting of pel- abrasive resistant. Feeder(s) set the rate to the TSE and a
gy areas. Leistritz Extrusion designs, manufactures and or high-volume production, Leistritz can supply the twin lets, powders and fluids. Barrels are modular and utilize controlled pressure gradient allows materials to be intro-
supplies twin screw extruders and turnkey systems for screw extrusion system to meet your needs! liquid cooling. Screws are segmented and assembled on duced into downstream zones via side stuffers and liquid
high torque shafts. Screw designs are shear intensive or injection systems.
passive, based upon the application. Metallurgies are
Co-rotating twin screw extruder screw set ZSE MAXX modular
process section
Vac Stuffer Stuffer Feed Heavy duty gearbox AC motor
Vent Vent
Co-rotating, intermeshing
twin screw set
Modular barrels
ZSE MAXX twin screw extruder Segmented screws
Laboratory scale Dispersive mixing element
High-volume production Flighted conveying element
Turnkey system
Distributive mixing element
» ZSE MAXX twin screw extruders are used Heavy duty gearing
for many processing tasks Modular barrel with insert liner and closures- metallurgies are matched
to the process
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↗ Overview ↗ Services
ZSE MAXX SERIES TEST, DON’T GUESS!
High free volume and high specific torque Fully equipped process development laboratory
The Leistritz ZSE MAXX twin screw extruder series uti- tric cartridge heaters for increased heating capacities and The Leistritz USA process development laboratory in-
lizes an OD/ID (outside diameter/inside diameter) screw improved maintenance. Another unique feature of the cludes various sizes of twin screw extruders, more than
ratio of 1.66/1 which facilitates a high free volume in the MAXX series is that each barrel section has two plumbing 40 feeders for pellets, powders and liquids, and a variety
TSE process section in combination with high torque. The inlets and outlets for increased coolant flow and better of downstream systems. A separate area is available for
combination of high volume and torque is made possible heat transfer capabilities. cleanroom testing. Pelletizing film, sheet and profile
by an asymmetrical splined shaft design. Barrels use elec- (including co-extrusion tooling) and supercritical liquid
injection systems are available.
Features
ZSE MAXX barrel with
Remote VPN
Asymmetrical splined shaft
cartridge heaters and
internal cooling bores Recipe
Heat transfer
Volume
Spare parts programs: We maintain all the necessary
CONTROL ARCHITECTURES
REMOTE SERVICING parts at our USA facility to keep you up and running.
Consignment arrangements are available upon request.
Torque
Quick support
Training: We offer Twin Screw Workshops that combine
Automation technology classroom training with “hands-on” machine demonstra-
tions. Since 1990 5000+ have attended Leistritz educa-
tional programs.
Leistritz offers various control architectures and options. Technical library: Technical literature relating to twin
Programmable Logic Controllers (PLCs), Human Machine In- screw extrusion technology is available for download via
terface (HMI) touchscreens, motors and drives are matched our website.
to in-house preferences. Systems can be accessed remotely
via a VPN access for system diagnostics and upgrades!
Ethernet IP
Trending Quick and economical service from afar! Safe and
encrypted remote access is available via VPN connec- Security access
Setpoints
HMI touchscreen tion for software updates, process and service related
Archiving
troubleshooting.
Specific energy
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↗ Extruder Range ↗ Extruder Range
TWIN SCREW EXTRUDERS TWIN SCREW EXTRUDERS
Laboratory scale and pilot plant Small lot, mid-size and high-volume production applications
There is a reason Leistritz has installed more TSEs at research institutions than anyone else. Integrating these systems All Leistritz TSEs are rated for 2₄ hr/day industrial scale production and are ideal for small lot specialty compounds,
is a Leistritz specialty. Whether it’s early stage research, formulation testing or pilot scale development, we have a TSE mid-range or high-volume production applications making pellets or parts. Complete systems may be specified,
designed for the task. Pelletizing and/or direct extrusion systems are commonly supplied. including upstream material handling equipment, dies and downstream systems, all fully integrated. Each system is
equipped with remote VPN access for troubleshooting and service.
Data acquisition Compounding
R&D
ZSE 18 with LHLG pelletizer
Flexibility of design ZSE 50 with air-quench pelletizer
Specialty applications
ZSE 27 HP with gear pump and underwater pelletizer
ZSE MAXX compounding plant for highly filled compounds
Reactive extrusion
Devolatilization
ZSE 40 MAXX with side stuffer, screen changer, gear pump, diverter and underwater pelletizer
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↗ Application ↗ Applications
MASTERBATCH AND COMPOUNDING
Very good quality of dispersion
Continuous mixing (compounding) of polymers with feeders. Downstream introduction of fillers and fibers
pigments, fillers, fibers and additives is the most com- often utilize a side stuffer, which is particularly beneficial
mon application for a TSE. Highly-filled formulations and for shear sensitive materials! Strand, hot face and un-
masterbatch production are Leistritz specialties. Pre-mix- derwater pelletizers are all commonly integrated into the
es that don’t segregate are often metered into the TSE. TSE system.
Multiple feed streams typically require loss-in-weight
ZSE 75 MAXX high filler loading system with two side stuffers
Engineering resins
ZSE 27 MAXX split-feed strand pelletizing system ZSE 35 MAXX twin screw extruder
PVCs Masterbatch
Blends and alloys
Highly filled formulations CBAs
Color masterbatch is a Leistritz specialty
FRs Fiber filled High liquid phase
Specialty compounds
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↗ Application ↗ Applications
DEVOLATILIZATION & REACTIVE EXTRUSION POST-REACTOR TSE SYSTEM
TSE systems Large scale compounding
Devolatilization (DV) is a process where unreacted mon- Leistritz TSEs may be integrated into reactive extrusion Leistritz twin screw extruders are utilized in the post-reactor process to compound additives into the polymer.
omer, solvent, water or other undesirable volatile con- (REX) systems, where a chemical modification and/or On-line rheological equipment can be integrated to monitor and control the molecular weight of the polymer.
taminants are removed from a polymer melt. Vacuum polymer synthesis occurs in the TSE. Screw design, tem-
level, residence time, surface area of the melt pool and peratures, rate and screw rpms all play a key role in the
surface renewal are all managed to facilitate DV efficien- final product properties.
cies. All/most TSEs include the provision for devolatiliza-
tion – sometimes as a critical factor, and sometimes an
PA PC
PP
after-thought.
Multi-stage venting
PE
Monomer
ZSE 180 MAXX post reactor plant
UVs
ZSE 18 underwater pelletizing system configured for REX AOs
Devolatilization Post-reactor
Reactive extrusion
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↗ Applications ↗ Applications
DIRECT EXTRUSION
Films, sheets, fibers
Direct extrusion refers to when raw materials are com- And eliminating the second stage single screw operation
pounded in a TSE and extrudated directly into the final saves cost. Direct extrusion systems can integrate gear
part, bypassing the pelletization step. Why do it? The pumps to achieve tight tolerances. Downstream systems
materials experience one less heat and shear history, are then matched to the specific application.
Gear pump and sheet die Coex PVB film system
which often translates into improved product properties.
Micro-27 @ 60/1 L/D configured for compounding and foam profile extrusion
ZSE 135 MAXX biaxial film system
Fibers
Foamed parts Film
Molded parts Filaments
Co-extrusion
ZSE 27 MAXX with gear pump and downstream sheet system
Sheet Profile
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↗ Applications ↗ Applications
PHARMACEUTICAL AND NUTRACEUTICAL
TSEs for various processes
Leistritz manufactures twin screw extruders (TSE) that
produce state-of-the-art pharmaceutical dosage forms.
Entrapped air, moisture and volatiles are efficiently re-
moved via venting in a TSE. A more consistent, repeata- Dissolvable films
Drying
Melt extrusion increases the bioavailability of poorly ble and uniform product is the typical result as compared
soluble active pharmaceutical ingredients (APIs), and to batch processes.
granulation extrusion processes facilitate continuous ZSE 27 micro-pelletizing system with in-line gauge, pelletizer and classifier
Micro-pellets
mixing and drying. For nutraceuticals the TSE is used to Containment systems and validation documentation are
mix, cook, dry, condition and increase the nutrient bio- commonly integrated into the cGMP system design, and
availability. a wide variety of downstream systems are available.
CHILL ROLL
Specialty lamination system for
transdermal, wound care and films ZSE 18 HP-PH extruding to the chill roll
NANO 16 twin screw extruder ZSE 18 HP-PH with micro-pelletizing system
– can process 50 grams or less
Nano-scale PAT Melt extrusion Solubility
Excipients
APIs Gel mass ZSE 60 in granulation format
Conditioning
Multi-functional devices
Transdermal
ZSE 27 HP-PH pharmaceutical
class twin screw extruder
ZSE 27 in
granulation format
Twin screw extruder with Fibers
glove box/containment features
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EXTRUSION TECHNOLOGY
Available for you all over the world
USA GERMANY CHINA
Leistritz Extrusion, Headquaters Leistritz Machinery (Taicang) Co., Ltd.,
Somerville, NJ Leistritz Extrusionstechnik GmbH, Taicang
Nürnberg
ITALY FRANCE SINGAPORE
Leistritz Italia Estrusione, Leistritz France Extrusion, Leistritz SEA Pte Ltd., Singapore
Castellanza Ceyzeriat
↗↗ Leistritz Extrusion, Business Unit of Leistritz Advanced Technologies Corp.
175 Meister Avenue | Somerville, NJ 08876 | USA
LEX-1 us 05/18
www.leistritz-extrusion.com
