KraussMaffei Extrusion Unveils New Side Feeder for Bulky Recyclates

(Photo: KraussMaffei Extrusion).

KraussMaffei Extrusion will showcase its new “ZSA UltraCycle” side feeder for twin-screw extruders at Fakuma 2026. Designed for the direct processing of lightweight, bulky recyclates, the system is intended to eliminate additional pre-treatment steps such as compaction or agglomeration. Typical applications include plastic flakes, film scraps and fibers from post-consumer and textile recycling streams.

The system is particularly aimed at materials with very low bulk densities, in some cases as little as 10 kg/m³. These include PET, (LD)PE and PP flakes, as well as PA and polyester fibers and fabrics. With such materials, throughput is often limited not by the processing capacity of the twin-screw extruder itself, but by the ability to feed the material into the process.

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The “ZSA UltraCycle” compacts the material as it is fed into the extruder. This allows material feeding, melting, compounding, degassing and filtration to be combined in a single continuous process. Eliminating separate pre-compaction can reduce both the number of process steps and the associated equipment and energy requirements.

(Photo: KraussMaffei Extrusion).

At the heart of the side feeder are two specially designed screws that compact the material and convey it into the feed zone of the “ZE BluePower” twin-screw extruder. Gravimetric dosing is maintained throughout the process, helping to ensure consistent throughput, precise formulation control and stable extrusion conditions.

The screws feature a modular design and can be adapted to different recycling materials and applications. Individual worn screw elements can be replaced separately, avoiding the need to replace the entire screw.

According to KraussMaffei Extrusion, trials at its Technology Center in Laatzen have demonstrated significant energy-saving potential. At a sample throughput of 1,000 kg/h, the company estimates that eliminating additional pre-compaction steps can save up to 400,000 kWh of electricity per year. Based on an electricity price of €0.15/kWh, this would equate to annual savings of around €60,000.

Fakuma 2026
Friedrichshafen, Germany
October 12–16, 2026
Hall A7, Booth 7303

More information: www.kraussmaffei.com

KraussMaffei Technologies GmbH, Parsdorf, Germany

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