Coperion's ZSK Pharma Extruder now available in size 26 and with new K3 Pharma feeder

The new K3-PH feeders from Coperion K-Tron are characterized by their minimal footprint and allow for a cluster-like arrangement around the process inlet. (Image: Coperion K-Tron, Niederlenz)

In addition to the well-known features of the ZSK Pharma extruder from Coperion, the new ZSK 26 is built even more compactly and can be cleaned very easily. (Image: Coperion, Stuttgart)

Coperion expands its proven ZSK extruder series with a new size in pharmaceutical design: With the ZSK 26, Coperion now offers a twin-screw extruder that meets all guidelines of the pharmaceutical industry and, depending on the application and the materials processed, covers throughput rates of 5-20 kg/h. The ZSK Pharma extruders are now available with the new, fully integrated K3 Pharma feeder. These and other new developments in dosing, extrusion, and material handling will be presented by Coperion and Coperion K-Tron at this year's Interphex.

In addition to the well-known features of its ZSK Pharma extruders, Coperion has equipped the ZSK 26 with some new developments. The process section of the ZSK 26 Pharma extruder is designed as a free-hanging unit, similar to the ZSK 18 size. Thanks to this new design, the process parts of the system are optimally accessible from all sides, greatly simplifying disassembly and cleaning. The dual-circuit cooling system, which uses water to ensure cooling of both the process section and the motor, is now fully integrated into the extruder's base frame. The vacuum pump and the KCM control unit for the highly precise Coperion K-Tron feeders are also housed there. These measures together result in a very compact overall extrusion system. Additionally, they enable quick and easy commissioning of the extruder on-site at the plant and facilitate production operation by separating the process-contacting and non-process-contacting areas.

Reproducible, high product quality

All Coperion ZSK Pharma extruders are compact, easy to operate, and designed for optimal access for cleaning and maintenance. To achieve maximum flexibility in the addition of liquids and solids, as well as in mixing and degassing the melt, Coperion uses a modular system for the extruder's process section. This consists of several housing elements in which equally rotating, self-cleaning screws operate. The independent Da/Di ratio (screw outer to inner diameter) of 1.55 allows for safe scaling across all ZSK Pharma extruders. The specific torque of 11.3 Nm/cm³ enables high throughput at low screw speeds and thus low product temperatures. The thermal load on the product components in the temperature-controlled ZSK process section is therefore low. Together with the tailor-made Coperion K-Tron dosing systems, the ZSK Pharma extruders ensure precise adherence to the recipe and reproducibly high product quality.

Highly accurate and customized dosing of ingredients

The new Coperion K-Tron K3 Pharma feeders are specifically designed for the increasingly demanded continuous processes of the pharmaceutical industry. Thanks to the smaller D4 platform scale with patented and highly accurate Smart Force Transducer (SFT) weighing technology, their footprint is significantly reduced compared to previous versions. The modular "Quick-Change" design of this innovative feeder line allows for quick and easy replacement of the feeder size and type, while the base unit (scale and drive) remains unchanged, enabling rapid adaptation to new formulations. The "Quick Change" design, where the dosing unit with horizontal agitator and screws can be quickly disconnected from the feeder drive, also ensures easy cleaning and quick product changeovers. The new K3 Pharma feeder is driven by a servo motor, which reduces its space requirement and extends the dosing range to include lower dosing rates. For optimal WIP cleaning (Wash-in-Place), the dosing unit is tilted by two degrees, ensuring the best possible drainage during the cleaning process.

Depending on the application, multiple K3-PH feeders can be grouped into a cluster, providing an ideal solution for continuous processes such as extrusion. Even for ingredients with demanding properties, such as highly viscous or sticky materials, powders that tend to fly, temperature-sensitive liquids, or substances with high hazard potential, Coperion K-Tron offers suitable dosing systems and accessories. In the case of the ZSK 26 Pharma extruder, the solid feeder is mounted on a swiveling platform directly above the extruder inlet. Liquid ingredients are fed via liquid dosing units installed on a separate stand next to the extruder.

Stefan Gebhardt, General Manager Business Unit Food & Pharma at Coperion, expresses his satisfaction with the new developments: "With the ZSK 26 in pharmaceutical design, we have successfully expanded our proven portfolio of pharma extruders to include an important throughput range. The positive response to our larger and smaller sizes in pharmaceutical design has been successfully transferred to the new ZSK 26. At the same time, we have equipped the extruder with additional features that further simplify handling during operation. Combined with our highly accurate K3 Pharma dosing systems, we are now capable of implementing complete extrusion lines for the continuous production of pharmaceuticals across nearly all throughput ranges."