Efficiency Boost at an EPS Plastics Processor Through Equipment Retrofit

When production stops every few days, efficiency and profitability take a hit. That was the case for a leading EPS plastics processor facing frequent downtime and significant material loss. Through a targeted equipment retrofit - centered around a continuous screen changer with backflush technology - the company not only eliminated unplanned stoppages but also saved 375 tons of material per year. Discover how this upgrade transformed their extrusion process and delivered a rapid return on investment.

Initial Situation

A leading EPS plastics processor and long-standing customer of KraussMaffei Extrusion aimed to increase the efficiency of its existing production plant by replacing a discontinuously working screen changer with a continuous one. The plant processed up to 7,500 kg/h of EPS material, but the discontinuous system led to frequent production interruptions.

Challenge

Screen changes were required approximately every five days, resulting in about one hour of production stoppage each time. During each stop, roughly 7,500 kg of EPS material was lost – a significant economic disadvantage and an unnecessary waste of valuable resources.

Solution

In close collaboration with the customer, the existing system was extensively retrofitted. At the core of the upgrade was replacing the discontinuous screen changer with a continuous one featuring a backflush function. This technology allows screen changes without interrupting production, significantly increasing overall line efficiency. Additionally, the customer can now process a higher share of recycled material because the screens can be cleaned in operation using the backflush function.

Results

• Tight schedule successfully met to the customer's full satisfaction
• No more unplanned downtime due to screen changes
• Weekly savings of approx. 7,500 kg of EPS material, totaling around 375 tons al per year
• Significant reduction in operating costs
• Fast return on investment thanks to higher system availability, reduced material losses, and increased use of recyclate

"QUOTE"

"The retrofit to a continuous screen changer was a real game-changer for our customer.
They are saving not only material but also time and maintenance costs — all while maintaining consistently high product quality."

– Project Manager Tim Wellmann, Krauss Maffei Extrusion –

Contact our experts today!

Discover how much more performance, efficiency, and uptime your existing EPS equipment could deliver.

Email us at [email protected].

FAQ

---

• What benefits does a continuous screen changer provide?
  A continuous screen changer allows filter changes during operation, preventing downtime. With backflush technology, screens can be cleaned frequently before an exchange is required, enabling higher recyclate use and lower operating costs.
• How much material can be saved with this retrofit?
  In this specific process the retrofit reduced material loss by approximately 7,500 kg of EPS every five days, resulting in savings of around 375 tons anually.
• What is the return on investment for the retrofit?
  The ROI is achieved quickly thanks to higher system availability, fewer production stops, and reduced material waste.
• Did the retrofit affect product quality?
  No. The continuous BKG® screen changer maintains consistently high product quality while increasing efficiency and reducing waste.