At Fakuma 2026, KraussMaffei Extrusion will present the new ZSA UltraCycle, a side-feed system for twin-screw extruders developed specifically for recycling.

KraussMaffei’s new ZSA UltraCycle.

The two screws of ZSA UltraCycle reliably conveys recycled materials into feed zone of ZE BluePower twin-screw extruder.

Suitable for mixed recycled plastics

The ZSA UltraCycle is specifically designed for fluffy recycled materials that pose challenges for conventional feeding systems due to their low bulk density of 10 kg/m³ or more and their high volume.

These include, for example, thin-walled flakes, film scraps, or plastic fibers from consumer waste, as well as fibers from textile recycling. Typical materials include PET, (LD)PE, and PP flakes, as well as fibers and fabrics made of PA and polyester.

Although the twin-screw extruder used has sufficient processing capacity, the material feed often limits the achievable throughput with these materials. The ZSA UltraCycle creates the conditions necessary to reliably utilize the extruder’s existing processing capacity.

Directly into the process, without any additional pretreatment

The new ZSA UltraCycle compacts the lightweight and the low-bulk density recycled materials during feeding, enabling continuous and reliable feeding of the twin-screw extruder. This eliminates the need for additional pre-treatment steps such as compacting or agglomeration.

At the same time, material feeding, melting, compounding, degassing and filtration can be combined in one continuous process. This reduces the number of process steps and lowers both equipment and energy requirements.

Efficient compaction, flexible screw design

At the heart of the newly developed side-feeding system are two screws, whose special design ensures efficient compaction of the material. This allows even large quantities of light recycled materials with a low bulk density to be reliably conveyed into the feed zone of the company’s ZE BluePower twin-screw extruder without compromising gravimetric dosing accuracy. The result is consistent throughput, high recipe accuracy, and stable process control.

The modular screw design also allows for flexible adaptation to different materials and applications.

The design also offers advantages when it comes to wear: Individual screw elements can be replaced selectively instead of having to replace the entire screw. This reduces downtime and lowers maintenance and spare parts costs.

Energy-saving potential confirmed

Trials conducted at the KraussMaffei Extrusion Technology Center in Laatzen (Germany) confirm the potential of the new solution.

By eliminating additional pre-compaction steps and enabling the direct processing of low bulk-density recycled materials, energy consumption and operating costs can be significantly reduced.

At an exemplary throughput of 1,000 kg/h, this results in potential savings of up to 400,000 kWh of electricity.

With the ZSA UltraCycle, KraussMaffei Extrusion makes the processing of lightweight and high-volume recycled materials easier, more efficient, and more cost-effective. The new solution reduces the number of process steps and energy consumption, thereby opening up additional potential for recycling materials that were previously difficult to process.