MAAG introduces the new M²-USG generation, a new underwater strand pelletizing technology, is designed to deliver enhanced process stability, higher throughput, and consistently superior pellet quality.

MAAG’s new M²-USG underwater strand pelletizing technology.

Design improvements combined with advanced sensor integration enable customers to achieve more reliable production and improved operational efficiency.

From polymer melt to pellets

The new system produces uniform, cylindrical pellets with minimal fines. During the process, the polymer melt passes through a die plate, is cooled and automatically guided into the pelletizer.

Precise control of process parameters is essential. Incorrect settings can cause strand adhesion, unstable cutting conditions, and ultimately production interruptions. The M²-USG addresses these challenges with a series of targeted design optimizations, which help maintain stable, efficient, and sustainable production.

Gentle strand handling in startup phase

The startup phase is often one of the most critical moments in pelletizing operations. During this stage, polymer strands must be reliably transferred into the guide system.

A newly developed scraper combines high operating speed with particularly gentle strand handling. The strands are cut sequentially at the die plate and fed into the strand guide section and the cutting head with a controlled time delay.

This significantly reduces the risk of strand sticking, clogging or excessive startup waste, resulting in faster and more reliable process ramp-up.

Seamless transition for enhanced stability

An optimized water film on the startup table prevents turbulence and reduces the risk of strands sticking together.

In addition, transport water is injected immediately after cutting, preventing potential blockages inside the cutting head, even when processing high-temperature polymers or challenging materials such as polycarbonate.

The result is smoother machine operation, improved process stability and increased system availability for the customer.

Larger cutting rotor for higher performance

The new cutting head features a compact and optimized design with improved sound insulation. The rotor diameter has increased from 162.5–200 mm, while the number of blades has grown from 30 to 36.

This upgrade enables significantly higher throughput while extending service life by 20%. A stable cutting gap ensures consistently high pellet quality and reduces maintenance requirements and spare-part consumption further lowering operating costs.

Higher reliability and product quality

The new development is engineered to ensure maximum system availability (>99% OEE) and highly stable production processes. Reduced downtime and minimized scrap rates help lower operating costs while improving overall plant profitability.

The newly developed M²-USG cutting head simplifies operation and maintenance. Maintenance procedures can largely be performed without tools, and cleaning times have been significantly reduced, allowing operators to return to production faster.

High capacity in compact design

The M²-USG is available in machine widths of 600, 900, and 1200 mm. At 600 mm width, the system achieves throughputs of up to 13,000 kg/h (PET), while the 1200 mm version reaches up to 24,000 kg/h - significantly exceeding the performance of previous models.

This higher capacity allows processors to achieve the same output with smaller machine sizes, reducing both capital investment and installation footprint.

Integrated sensors for monitoring

Integrated sensors continuously monitor key parameters such as vibration, temperature, flow rates, and pressure to ensure an optimal production at the sweet spot. Any deviations are immediately detected and reported, also via remote monitoring, helping operators prevent process instability and scrap.

A camera system also monitors strand flow, while compressed air consumption is also tracked. In addition, energy-efficient reluctance motors contribute to lower energy consumption and improved sustainability.