K 2025 Spotlight on Extrusion: Empowering the Future with Expertise and Purpose
Performance. Perfected. For you – with this slogan, KraussMaffei will be presenting at K 2025 (Düsseldorf, October 8th – 16th) how leading-edge technologies and a top customer orientation provide measurable added value. The focus of extrusion technology is on solutions for more efficient and future-oriented plastics processing – from large-scale industrial polymer production to pipe and profile extrusion and to efficient recycling processes. The trade fair appearance will be supplemented by digital innovations to enable smart, low-operator production.
The development roadmap for the coming years is clearly defined: “We are working specifically on new developments to continuously increase customer benefits, actively maintaining our products and resolutely driving forward the digitalization and automation of our products.” This is how KraussMaffei Extrusion is creating the foundation for sustainability, economic success and technological progress. “And we are making this tangible for visitors at K 2025 in Düsseldorf,” says Ralf Benack.
Future market petrochemicals: New processing extruder for raw polymer production
One of the latest significant advancements is the latest generation of ZE Petrochemical (ZE-PC) compounding extruders, specifically designed for the high requirements of large-volume polymer manufacturing. Drawn from the successful BluePower technology, the co-rotating twin-screw extruders – with screw diameters up to 400 mm – integrate energy efficiency with superior processing quality.
“Thanks to a D/d ratio of 1.65, torque densities of up to 16 Nm/cm³, and variable-speed drives, the machines can run at lower screw speeds without compromising throughput. This lowers the specific drive power and reduces the melt temperatures, which lowers the risk of degradation,” explains Dr. Thomas Unger, Vice President Technologies at KraussMaffei Extrusion. At the same time, the larger diameter ratio ensures significantly more effective degassing. “This allows us to offer our customers an economical, reliable and material-friendly solution,” he adds.
“Performance. Perfected. For you. reflects our commitment to delivering advanced extrusion solutions – technically refined, highly efficient, and consistently geared to the requirements of our customers, Our strength lies in the combination of highly developed mechanical engineering and deep process know-how – all from a single source, reliably delivered worldwide.” – Ralf Benack, Managing Director of KraussMaffei Extrusion GmbH
Increased output, reduced investment – cost-optimized recycling processes
Bottle-to-bottle PET recycling to material preparation for chemical processes – as a circular economy innovation driver, KraussMaffei Extrusion provides trailblazing solutions for any type of recycling. In the field of PET recycling, KraussMaffei Extrusion is showing a high-performance twin-screw system from the BluePower series for throughputs of up to 12 tons per hour. The technology answers the growing need for greater output and more energy- and cost-effective processing. It is up to 20% lower in energy consumption compared to traditional twin-screw systems. They are compatible with standard SSP units and yield food-grade rPET.
In chemical recycling, KraussMaffei Extrusion is focusing on key technologies: high-performance extruders for processing material streams – for example, to produce pyrolysis oils – efficiently implement crucial process steps such as dewatering, degassing and the removal of impurities. Pressures of up to 200 bar and the retractable UltraGlide system with easy-to-maintain screws enable customized solutions for demanding recycling applications.
KraussMaffei Extrusion has also refined its EdelweissTechnology for processing recyclates more efficiently – even with fluctuating material properties. The focus is clearly on process optimization and cost efficiency. The twin-screw extruder covers all process steps: degassing, filtering and compounding. “This integrated setup can lower investment costs by up to 25%,” says Dr. Thomas Unger.
More efficient research, more economical production: ZE BluePower in a new design
Whether for research or daily production – the new generation of the ZE BluePower twin-screw extruders offers clear advantages. The new ZE 28 BluePower scores with improved operation, greater energy efficiency and digital networking via ppC (pioneer processControl). The larger ZE 42-80 series has also been comprehensively redesigned – with a focus on simple maintenance, digital interfaces and an optimized modular system. “For our customers, this means a better price-performance ratio and shorter delivery times – real advantages in day-to-day operations,” says Dr. Thomas Unger.
New multilayer pipe head processes up to 100% recyclate
With its newly developed PVC multilayer pipehead, KraussMaffei Extrusion is demonstrating how pipe and profile extrusion can be made more sustainable and future-proof. The system processes up to 100% recycled PVC – even with varying material quality. The layer configuration can be flexibly adjusted depending on the application. A newly designed flow system prevents spiderlines and ensures consistent product quality with optimal material usage.
Digital transformation: rethinking machine control
With the new ppC (pioneer processControl) control system, KraussMaffei is bringing greater clarity and efficiency to extrusion processes. Instead of complex operating logic, ppC relies on intuitive processes, clearly structured user guidance and a unified user interface. This shortens the learning curve, reduces the amount of training required and makes everyday production easier. Its modular design enables use across all extrusion tasks – from Flat & Foam to Pipe & Profile through to Compounding and Recycling.
Integration into existing systems is also easy: interfaces for connecting to third-party devices such as metering devices, measuring systems and higher-level systems such as MES or DCS enable the central operation and monitoring of entire systems. This ensures greater transparency and process reliability.
Looking ahead: on the way to production without operators
In view of growing staff shortages, KraussMaffei Extrusion is developing digital tools for production without operators (PWO). Start-up workflows, AI-supported assistants and HMI solutions for mobile use make it easier to monitor entire lines – with fewer personnel. The first systems are already running unmanned at weekends – a milestone towards lights-out manufacturing.
Tailor-made Lifetime Service for maximum system efficiency
With its Lifetime Service, KraussMaffei Extrusion offers a comprehensive service concept that goes far beyond routine maintenance. “From commissioning and targeted modernization and data-based services, we support our customers throughout the entire life cycle of the system – reliably, proactively and with personalized solutions,” says Ralf Benack. Whether it’s spare parts, remote support, training, or digital condition monitoring, the goal is always the same: maximum plant availability, consistent product quality, and a sustainable boost in overall efficiency.
Editor in Chief
Performance. Perfected. For you.
KraussMaffei Extrusion’s presence at K 2025 underlines its commitment to combining innovative technologies, sustainable solutions and maximum cost-effectiveness in perfectly coordinated system solutions – individually tailored to customer requirements along the entire polymer processing value chain.
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