EXTRUTEX Coperion ZSK Compatible Screw Elements and Barrels

1. ZSK Compatible Replacement Parts – Technical Data

EXTRUTEX supplies replacement tooling for a range of ZSK twin screw extruder models. Material selection, dimensional requirements and inspection procedures are confirmed according to the individual part specification.

2. ZSK Series Coverage

Our replacement tooling covers selected machines in the ZSK Mc and Mc18 ranges. We also evaluate Mc11 variants and other configurations according to the technical information supplied by the customer.

If your machine model is not listed, provide a photograph of the machine nameplate, the relevant component and any available technical drawing. This information helps us identify the correct configuration before manufacturing.

3. What Does Dimensionally Interchangeable Mean?

For an aftermarket screw element to be interchangeable, it must reproduce the critical dimensions and geometry required by the original screw assembly. A similar outside diameter alone is not sufficient to establish compatibility.

The element must fit the shaft, maintain the correct relationship with the second screw and reproduce the intended screw geometry. This is particularly important in co-rotating twin screw extruders, where the two screw assemblies operate in a closely controlled arrangement.

Important Compatibility Dimensions

• Spline and keyway: The internal connection must match the corresponding shaft geometry.
• Outer diameter: The element must match the specified screw diameter.
• Pitch: The conveying geometry must reproduce the required axial pitch.
• Centre distance: The two screw axes must maintain the correct relationship.
• Stagger angle: Kneading blocks and other angled elements must follow the specified orientation.
• Element length: The axial length must match the intended screw configuration.
• Clearance: The assembled geometry must maintain the required operating clearances.

4. EXTRUTEX Screw Elements for ZSK Extruders

Screw elements determine how material is conveyed, compressed, mixed and processed through a twin screw extruder. Different element geometries are arranged along the shaft to achieve the required process conditions.

Conveying Elements

Conveying elements move material along the screw channel. Their pitch, length and flight geometry influence material transport and the available filling conditions. Different conveying configurations can be selected according to the process design.

EXTRUTEX supplies replacement conveying elements for compatible ZSK machines, manufactured according to the relevant original dimensions and element arrangement.

Kneading Blocks

Kneading blocks are used in mixing and dispersive processing sections. Their stagger angle and disc configuration influence the material flow and mechanical working of the compound.

Replacement kneading blocks can be manufactured according to the required number of discs, element length, stagger angle and shaft connection.

Mixing Elements

Mixing elements are designed to improve material distribution and homogenization. Their geometry varies according to the intended function and the position within the screw configuration.

Special Screw Elements

Special screw elements may be required for particular processing stages, formulations or machine configurations. EXTRUTEX can evaluate these components using drawings or reference samples.

5. ZSK 58Mc and ZSK 70Mc Replacement Parts

The ZSK 58Mc and ZSK 70Mc are two distinct machine sizes within the ZSK Mc range. EXTRUTEX manufactures compatible replacement screw elements and related components for both models.

Although the two models belong to the same machine family, their screw diameters, element dimensions and barrel bores differ. Parts should therefore be specified separately for each machine.

ZSK 58Mc Components

Replacement tooling for the ZSK 58Mc can include conveying elements, kneading blocks, mixing elements, screw shafts and barrel components. Individual worn parts can be supplied for maintenance, while complete matched sets can be considered for planned overhauls.

ZSK 70Mc Components

EXTRUTEX also supplies replacement tooling for the ZSK 70Mc. Each component is manufactured according to the required machine dimensions and screw configuration. Correct identification of the model and component position is important when ordering.

6. ZSK 92 Screw Element Replacement

The ZSK 92 is a widely used machine in the 92 mm twin screw compounding class. EXTRUTEX supplies replacement conveying elements, kneading blocks and shafts for ZSK 92 Mc and Mc18 configurations.

Replacement elements are machined according to the corresponding OEM profile and dimensional requirements. Where the existing shaft and screw configuration are suitable, individual elements can be replaced without changing the complete screw assembly.

Available ZSK 92 Replacement Components

• Conveying screw elements.
• Kneading blocks with specified stagger angles.
• Mixing and special screw elements.
• Replacement screw shafts.
• Barrel sections and related wear components.
• Individual components or complete matched screw sets.

Dimensional inspection is carried out for each production batch. CMM reports can be provided to document the measured dimensions of the supplied components.

7. ZSK 133 Screw Element Replacement

The ZSK 133 is a larger twin screw extruder configuration used in demanding industrial compounding applications. Screw elements operating in melting and mixing zones can experience significant mechanical loading and wear depending on the formulation and process conditions.

EXTRUTEX manufactures ZSK 133 replacement elements using PM-HIP material options, including the specified 1.2379 and 1.2380 grades. Parts can be supplied individually or as matched sets for scheduled maintenance and overhaul projects.

ZSK 133 Supply Options

• ZSK 133 Mc compatible screw elements.
• PM-HIP steel replacement elements.
• Conveying and kneading components.
• Single replacement pieces.
• Matched screw element sets.
• Dimensional inspection reports per batch.

Due to the size and weight of some ZSK 133 components, freight arrangements should be confirmed separately. Complete sets can be evaluated for sea or air freight according to shipment requirements and delivery priorities.

8. PM-HIP Materials for Screw Elements

Powder metallurgy materials produced using hot isostatic pressing are used for demanding screw element applications. The PM-HIP process consolidates metal powder under high temperature and pressure to produce a dense material structure.

EXTRUTEX offers PM-HIP material specifications including 1.2379 and 1.2380 for suitable replacement screw elements. Final selection depends on the application, material compatibility, wear conditions and customer specification.

PM-HIP 1.2379 and 1.2380

These material designations are included in the available PM-HIP tooling specifications. Their use should be confirmed against the approved material documentation and required mechanical properties.

Nitrided 38CrMoAlA

38CrMoAlA is an alloy steel commonly specified for nitrided industrial components. It is included in the EXTRUTEX material options for suitable screw and barrel parts.

9. ZSK Compatible Extruder Barrels and Barrel Sections

Barrel components form the housing around the twin screw assembly. Their internal geometry, bore dimensions and relationship with the screw elements are essential to the operation of the extrusion system.

EXTRUTEX supplies compatible barrel components for selected ZSK Mc series machines according to the relevant technical drawings and dimensional requirements.

Barrel Manufacturing Considerations

• Correct barrel bore dimensions.
• Matching machine configuration and screw diameter.
• Compatible barrel connection and mounting dimensions.
• Specified base material and treatment.
• Internal surface condition and dimensional accuracy.
• Correct alignment with adjacent barrel sections.

Barrel replacement parts should be specified using the machine model and exact barrel position. Different sections may have different internal functions and connection arrangements.

10. Quality Control and Dimensional Verification

Dimensional accuracy is essential for aftermarket screw elements and barrel parts. A component that appears similar to the original may still cause assembly or operating problems if its critical dimensions are incorrect.

EXTRUTEX uses dimensional inspection to verify manufactured parts against the relevant technical requirements. A coordinate measuring machine (CMM) report is available per batch.

Inspection and Documentation

11. Chinese Standard Machine Compatibility

In addition to imported-machine replacement tooling, EXTRUTEX supplies screw elements and barrel components for selected Chinese standard twin screw extrusion machines.

The Chinese machine manufacturers and equipment brands identified for this supply category include:

• KY
• Jieya
• Chuangbo
• Cenmen
• Meizhilong
• Jwell
• Useon
• Kerke

Stock availability depends on the specific machine model and component. Ex-stock dispatch is possible for confirmed available parts. Imported-machine spare parts generally require approximately 30–45 days after material availability and drawing confirmation.

12. Individual Replacement Parts or Complete Screw Sets

Customers can order individual components or complete matched screw element sets according to their maintenance requirements.

Individual Component Replacement

Replacing one or several worn elements can be appropriate when the remaining screw assembly is in suitable condition and the replacement parts are dimensionally compatible. The position and orientation of each replacement element should be confirmed before installation.

Complete Screw Set Replacement

A complete screw set can be considered for a planned overhaul, major maintenance project or new screw configuration. Matched sets allow the complete arrangement to be reviewed together rather than treating each component as an isolated replacement.

13. Ordering and Manufacturing Process

To reduce the risk of ordering incorrect replacement components, EXTRUTEX recommends a technical confirmation process before production.

1. Machine identification: Confirm the machine manufacturer, model and series.
2. Component identification: Specify the element, kneading block, shaft or barrel section required.
3. Drawing review: Submit original drawings or reference dimensions.
4. Material confirmation: Select the required material and treatment specification.
5. Manufacturing confirmation: Confirm quantity, inspection requirements and delivery arrangements.
6. Production and inspection: Manufacture the components and complete the agreed dimensional checks.
7. Packing and dispatch: Prepare inspection documents and shipping arrangements.

14. Information Required for a Quotation

Providing accurate machine and component information helps us identify the correct replacement part and prepare a suitable manufacturing specification.

15. Frequently Asked Questions

16. Request ZSK Compatible Screw Elements and Barrel Parts

EXTRUTEX supplies aftermarket screw elements, kneading blocks, shafts and barrel components for selected Coperion ZSK Mc series twin screw extruders. Whether you require one replacement element for urgent maintenance or a complete matched screw set for an overhaul, our team can evaluate your machine specifications and manufacturing requirements.

For faster technical confirmation, send the machine nameplate photograph, component position, existing part photographs and available drawings. Our team can review the required dimensions, material specification, inspection documentation and delivery schedule.