Coperion’s modular turnkey compounding systems for maximum added value

Phil Black - PII Editor 03/05/2012

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Coperion has set itself the strategic aim of strengthening its position in the market for complete turnkey compounding plants for the plastics industry. By offering these complete solutions Coperion implements compounding plants in the shortest time possible on a fixed cost basis. The customer has only one supplier and only one contact person from start to finish, from the initial planning and design stage through to the engineering and the production of the individual units and the final commissioning of the installation.

A special feature in the segment of turnkey compounding plants are the systems in modular design. Coperion’s Modular Turnkey Systems (MTS) are custom designed with standardized, pre-assembled modules that have been integrated into a steel structure that expedites delivery and installation. From raw material handling to the ZSK twin screw extruder and all downstream equipment, plant design is optimized to meet customer’s requirements. Before delivery, the modules are assembled at Coperion and pre-tested prior to delivery, which can be witnessed by the customer. Coperion’s modular plants are available in a wide range of capacities ranging from ZSK 26 laboratory extruder to complete system for a ZSK with 133 mm.

So far, more than 70 modular turnkey systems have been installed in China, Europe, North America, South America and the Middle East with some processes involving very complex setups.

For instance a line for filled polyolefins with 17 feeders for raw materials and additives and a capacity of approximately 5 metric tons per hours was implemented on green field site in only 15 months from order to start of production. From engineering and assembly, to the commissioning of the compounding plants, Coperion integrates all of a system’s components with one another on a fixed cost basis. The entire time schedule is specified at the start of the project right through to delivery, installation and commissioning. Silos, conveying and metering equipment for the raw material, the core ZSK twin screw extruder, all downstream peripheral equipment including finished product handling and bagging, and the fully integrated control system for the entire process are all coordinated through a single source, saving compounders considerable effort in planning and procurement.

The custom tailored, fully tested system modules can be quickly installed and are ready for operation in shortest time after utility hook up. Coperion’s worldwide service network supports on-site installation and commissioning and offers the training of operating personnel before delivery and comprehensive after-sale service, making an MTS plant an ideal solution for setting up production facilities in emerging market countries. The steel structure of the modular systems eliminates the need for rigorous building requirements, allowing the plant to be housed in a simple shell, warehouse type building. Due to the modular concept the entire plant can easily be relocated if the market situation changes. With the modular concept plant duplication in multiple locations becomes very easy and convenient.