All-in-one ZSK FilCo filtration compounder optimizes PCR and polymer recycling

Coperion developed the innovative ZSK FilCo filtration compounder which allows filtration and compounding in a single production step for recycling of post-consumer recyclate (PCR) and any highly contaminated polymer.

All processes in single system

The new machine can melt, filter compound and pelletize recyclate in a single production system.

Firstly, waste plastic, in the form of regrind, fiber pellets, film flakes or agglomerate, is fed into the ZSK extruder and is melted, homogenized and devolatilized there together with all its components (all polymers, PE, PP, PA, PS, PC/ABS, etc).

After that, the melt is fed through an integrated filter that removes all contaminants.

Then, the melt is reintroduced into the ZSK extruder process section, where reinforcing materials are added, such as glass, wood and carbon fibers, or fillers like talc, CaCO3 and ground PEX. Lastly, the recompound is pelletized.

Coperion’s ZSK FilCo filtration compounder.

Higher energy efficiency and product quality

As the recyclate requires melting process for only once, the new production system offers a list of advantages.

Compared to multi-part systems, it requires less space to operate. Besides that, it can consistently achieve higher product quality than typical multi-part system.

Furthermore, energy consumption and emissions for the extrusion process are significantly reduced. With the twin screw extruder’s high mechanical energy input, the melting process is more energy efficient than with a single screw extruder.

Eliminated second melting process for compounding and omitted pelletizing of intermediate compounds also contribute to the reduced energy consumption.