(Düsseldorf/Laatzen, June 16^th 2025) Performance. Perfected. For you - under this motto, KraussMaffei will be demonstrating at K 2025 (Düsseldorf, October 8^th – 16^th) how cutting-edge technologies and a strong customer focus deliver measurable added value. The spotlight in extrusion technology is on solutions for more efficient and future-proof plastics processing – from large-scale industrial polymer manufacturing to pipe and profile extrusion and to cost-effective recycling processes. The trade fair presentation will be complemented by digital innovations paving the way towards smart, low-operator production.

“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”, says Ralf Benack, Managing Director of KraussMaffei Extrusion GmbH. “Our strength lies in the combination of highly developed mechanical engineering and deep process know-how – all from a single source, reliably delivered worldwide.”

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.

One of the recent key developments is the new generation of ZE Petrochemical (ZE-PC) compounding extruders, purpose-built for the demanding needs of large-scale polymer production. Based on the proven BluePower technology, the co-rotating twin-screw extruders – available with screw diameters up to 400 mm – combine energy efficiency with high 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.  

From bottle-to-bottle PET recycling to material preparation for chemical processes - as a driver of innovation in the circular economy, KraussMaffei Extrusion offers pioneering solutions for all forms of recycling.In the PET recycling sector, KraussMaffei Extrusion is presenting a high-performance twin-screw system based on the BluePower series for throughputs of up to 12 tons per hour. The concept responds to the increasing demand for higher output and more energy- and cost-efficient processing. Compared to conventional twin-screw systems, energy consumption can be reduced by up to 20%. The systems are compatible with standard SSP units and produce 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.

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.

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.

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.

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.

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.

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.

KraussMaffei at K 2025
Hall 15, Stand C24