Gneuss KSF Series - Compact Continuous Polymer Melt Filtration Systems
One of the most important factors determining final product quality in plastic extrusion and recycling processes is the efficient and reliable filtration of the polymer melt. During extrusion, gel formations, solid particles, and foreign contaminants present in the polymer melt can directly affect product quality. For this reason, modern plastic production facilities utilize high-performance polymer melt filtration systems.
Developed by the German technology company Gneuss, the KSF Series Rotary Filtration Systems are compact and continuously operating melt filtration solutions specifically designed for production lines where frequent material and color changes occur. Using Gneuss's patented Rotary Filtration Technology, these systems enable uninterrupted filtration during the production process.
KSF series filtration systems are widely preferred in the plastics processing industry, particularly in the following applications:
• plastic extrusion lines
• PVC processing and recycling applications
• film and sheet production
• compounding and masterbatch production
• fiber and filament manufacturing
• recycled plastic processing lines
Thanks to their compact design, high pressure resistance, and rapid filter change capability, KSF series systems provide high filtration efficiency and stable process control in plastic production lines.
Gneuss Rotary Filtration Technology
The core technology behind Gneuss filtration systems is the rotary disk filtration system. In this system, filter disks rotate continuously within a circular structure, allowing filtration to continue without interrupting the production process.
The key operating principles of this technology are:
• continuous melt flow
• continuous renewal of the active filtration surface
• automatic filter change
• filtration without stopping production
As the filter screens on the rotating disk pass through the melt channel, solid particles in the polymer melt are retained on the filtration surface. When the filtration surface begins to clog, the system detects the increase in upstream pressure and automatically rotates the filter disk to bring a clean filtration surface into the melt flow.
As a result, the following parameters remain stable throughout the production process:
• process pressure
• melt temperature
• melt viscosity
• production capacity
Thanks to rotary filtration technology, pressure drop across the melt flow remains under continuous control, ensuring stable process conditions in the production line.
Technical Features of the KSF Series
Gneuss KSF Series filtration systems are designed for extrusion lines operating under high pressure conditions. The modular design of the system allows it to be used with a wide variety of polymer types.
Maximum operating pressure
The system can provide leak-free operation at pressures of up to 500 bar when processing low-viscosity polymer melts.
Filtration fineness
Depending on the filter element used, filtration fineness can be reduced to approximately 10 microns.
Filter reusability
Filter screens can be reused up to 400 times when cleaned using appropriate procedures.
Active filtration area
Despite their compact design, KSF systems provide a large active filtration area capable of supporting high production capacities.
Heating system
KSF filtration systems can operate with different heating configurations:
• electric cartridge heating
• thermal oil heating
This flexibility allows easy integration into various extrusion lines.
Compact Design and High Pressure Resistance
One of the most significant features of the KSF series filtration systems is their compact design.
This compact structure offers several advantages:
• easy integration into existing production lines
• lower installation costs
• suitability for limited installation space
The metal sealing system used in the filtration unit provides high wear resistance and ensures leak-free operation even when processing low-viscosity polymer melts.
Rheologically Optimized Melt Flow Channels
The melt flow channels used in the KSF series systems are designed with rheologically optimized geometry.
This design provides several advantages:
• reduced pressure loss
• homogeneous melt flow
• short melt residence time
• reduced risk of thermal degradation
These features are particularly beneficial when processing thermally sensitive polymers.
Automatic and Continuous Filter Change
In KSF series systems, filter changes can be performed without stopping the production line.
When the upstream pressure reaches a predefined value during filtration, the system automatically activates a new filtration surface.
During the filter change process:
• the polymer flow temporarily passes through three filtration cavities
• pressure spikes are avoided
• process stability is maintained
This feature ensures uninterrupted operation and consistent product quality in the production line.
Ideal System for Frequent Material and Color Changes
KSF series filtration systems are particularly designed for production lines with:
• frequent material changes
• frequent color changes
• batch production processes
• PVC extrusion applications
These systems allow quick transitions during material changes with minimal production losses.
Impact on Product Quality
High-performance filtration systems significantly improve final product quality in plastic production.
The key quality advantages provided by the KSF series include:
• reduction of gel formations
• removal of particulate contamination
• more homogeneous melt flow
• reduced filament breakage
• protection of downstream processing equipment
As a result, stable production and high product quality can be achieved in extrusion lines.
Application Areas
Gneuss KSF series filtration systems are used across various sectors of the plastics processing industry.
Film production
• blown film
• cast film
• multilayer film
Fiber and filament production
• technical yarns
• textile filaments
• nonwoven production
Pipe and profile production
• PVC pipes
• HDPE pipes
• plastic profiles
Compounding applications
• masterbatch production
• filled polymer compounds
Plastic recycling
• PET recycling
• PE recycling
• PP recycling
Importance of Filtration in Plastic Recycling Processes
Raw materials used in recycling applications often contain high levels of contamination.
These contaminants may include:
• metal particles
• paper and label residues
• carbonized plastic fragments
• gel formations
Gneuss rotary filtration systems remove these contaminants efficiently, ensuring stable and high-quality melt flow in the production line.
Industrial Advantages of Gneuss Filtration Systems
Gneuss filtration technologies have been used in the plastics processing industry for many years and are widely adopted in production facilities worldwide.
The main advantages of these systems include:
• uninterrupted production
• high filtration efficiency
• low maintenance costs
• energy savings
• long equipment lifetime
• stable process conditions
Thanks to these features, Gneuss filtration systems are recognized as high-performance filtration solutions in the plastics processing industry.
