Compounding system DCIM

Product overview
With Direct Compounding Injection Molding (DCIM), an additional single‑screw extruder is integrated inline on a standard injection molding machine, enabling direct compounding of thermoplastics in one discontinuous process. This reduces material costs, allows development of in‑house formulations and lowers CO2 emissions.

Key benefits

• Significantly reduce material costs
• Tailor‑made material properties
• Secure competitive advantage through recipe know‑how
• Drastically reduce your carbon footprint
• Sustainable and material‑friendly production
• Replace complex multi‑stage processes

Testimonial
‘The material quality lies with DCIM at ZF, and we have protected the expertise in‑house, fully documented and tested.’

• Achim Härtel — Core Engineer Plastics at ZF Alfdorf / Germany

Single-screw extruder

• Space‑saving piggyback position on the injection unit
• Special screw design engineered for material compounding
• Process length extended to 30 L/D for optimum material homogeneity
• Discontinuous operation tailored to the injection molding process
• Fully integrated into the injection molding machine

Gravimetric single-component dosing

• Individual component weighing
• Dosing device matched to type of raw material
• Partially integrated into the machine control system
• Proven dosing technology from the compounding industry
• Options from economical gravimetric batch blenders to high‑end loss‑in‑weight devices

Standard injection unit

• Injection unit with 3‑zone screw and melt transfer
• Short and flow‑optimized melt transfer from extruder to injection unit
• Genuine melt temperature measurement and pressure monitoring at the transfer point
• Injection using a standard injection unit with 3‑zone screw
• Automatic coordination of extrusion and injection molding by the machine control system

Material feed for production without pre-compounding

• Standard material hopper on the flange of the injection cylinder
• Easy selection and deselection of the compounding extruder via the control panel
• Versatile application: machine can operate as standard SGM without extruder

Extensions / Combination options

• Combination with various KraussMaffei injection machine series (examples shown: CX series, GX series, PX series)
• Options to upgrade machines and combine DCIM with automation and digital solutions

Technical specifications

• Process name: DCIM (Direct Compounding Injection Molding)
• Core concept: additional single‑screw extruder adapted inline to standard injection molding machine
• Extruder screw length: extended up to approx. 30 L/D for optimum homogeneity
• Dosing: gravimetric single‑component dosing; optional loss‑in‑weight systems; individual component weighing
• Injection unit: 3‑zone screw; melt transfer optimized with temperature and pressure monitoring at transfer point
• Operation: discontinuous mode coordinated with injection cycle; extruder can be selected/deselected
• Integration: fully integrated into injection molding machine control
• Material handling: standard hopper on injection cylinder flange; supports production without pre‑compounding
• Primary benefits: material cost reduction, in‑house recipe development, reduced CO2 footprint, sustainable production