VDW Verein Deutscher Werkzeugmaschinenfabriken e.V.

At the heart of this innovation is the direct compounding of the PC melt, straight from the final polymerization reactor outlet with various polymers (like ABS) or additives. This eliminates the need for separate and additional compounding facilities and simplifies the overall PC compounds production process considerably.

One of the most significant advantages of this one-step process is the substantial reduction in energy consumption. The PC melt now is directly transferred from the final polycarbonate polymerization reactor, together with other plastics like ABS and additives, into a special one-step direct compounding extruder. The Coperion ZSK twin screw extruder mixes and homogenizes the ready-made PC compound melt before the final pelletizing step. This new technology eliminates the need of an intermediate PC granules storage and further PC chips conveying systems towards a separate compounding facility. It also eliminates the reheating/re-melting of a 2nd step extrusion system, overall resulting in a significant increase in energy efficiency. Therefore, and depending on the product mix, operational cost savings of up to 1 million USD per 100 kta can be achieved.

Through this new technology, capital expenditures are also drastically reduced as there is no need for additional compounding plants/facilities or supporting infrastructure. The entire process can be carried out within one integrated direct-compounding process step and related machine setup, allowing for streamlined operations and reduced complexity.

Moreover, this process provides maximum flexibility, enabling the producers to quickly adjust or adapt product formulations based on changing market demands. This ensures fast market-response times, increased product diversity, and sustainable long-term competitiveness.

About Coperion

Coperion (www.coperion.com) is a global industry and technology leader in compounding and extrusion systems, size reduction, washing, separating, drying, agglomeration, feeding, weighing, material handling and pneumatic conveying systems, as well as milling, mixing, thermal processing, dust collection and other services. Coperion develops, produces, and services plants, machinery, and components for the plastics and plastics recycling, chemical, battery, minerals, food and pharmaceutical industries. Coperion employs more than 5,000 people in its three divisions, Performance Materials, Food, Health & Nutrition, and Aftermarket Sales & Service - at over 50 sales and service locations worldwide. Coperion is an Operating Company of Hillenbrand (NYSE: HI), a global industrial company that provides highly-engineered, mission-critical processing equipment and solutions to customers serving a wide variety of industries around the world. www.hillenbrand.com

About EPC Engineering & Technologies GmbH:

EPC is an internationally active technology provider, engineering and plant construction company head-quartered in Arnstadt, Germany. With decades of experience in chemical, polymer, and industrial plant technologies and engineering, EPC offers tailor-made solutions for process optimization, plant design, and project implementation.