PCS Co-KneadersThe specialist for powder coatings & thermosets

BUSS compounding technology developed further for optimized performance

The PCS is a further development of the classical BUSS Co-Kneader, specifically for the use of powder coatings and thermosets. While it retains the proven operating principles of the BUSS Co-Kneader, the process section in particular has been developed for the requirements of modern formulations.

The extended BUSS Co-Kneader series PCS sets benchmarks for profitability, availability and user-friendly handling. Its extended process length and increased screw speed enable optimum quality powder coating formulations with the same configuration, simply by adjusting the process parameters.

BUSS PCS Co-Kneaders are also highly suitable for processing thermosets. In order to exploit the superlative qualities of EMC, compounding systems must ensure excellent dispersion of the high filler content at low and perfectly controlled temperatures.

BUSS compounding technology has routinely met these high requirements for 60 years and is equally ideal for epoxy-based, phenol-based, polyester-based, melamine and urea-based resin molding compounds.

Our long-standing experience enables the optimum selection of the materials in order to minimize machine downtimes and maintenance work.

BUSS PCS Co-KneadersFocus on customer benefits

Process Section – The PCS process section is designed in 11 L/D as a standard variant and additionally available in 8 or 14 L/D. The process length has a significant impact on the residence time and thus the shear intensity that can be generated. The standard process length of 11 L/D allows for the processing of an extremely wide range of formulations, from structural to high-gloss coatings, without the need to change the screw configuration. Systems specifically for structural or highly reactive products can be designed in 8 L/D and for high-gloss in 14 L/D. Optionally, the process section can be equipped with a second inlet to add aluminum effect pigment or highly reactive cross-linking additives. The proven working principle of the co-kneader ensures excellent self-cleaning, enabling quick color and formulation changes.

Precise Temperature Profile – Thermocouples can be installed in drilled kneading pins at various points along the process section. A precise feedback of the melt temperature is ensured by the fact that the thermocouple pins are in direct contact with the product melt. The combination of liquid heating and cooling systems, as well as the extremely precise monitoring of the melt temperature, are essential factors for the successful processing of temperature-sensitive products – especially with highly reactive formulations. Additionally, online temperature measurement allows for the detection of the slightest fluctuations in the process, ensuring quality at all times.

Maintenance Friendliness – Easy handling and the shortest changeover times during product changes further enhance the high availability of the PCS series. For cleaning and inspection, the kneader housing can be fully opened within minutes. Additionally, the modular design of the process elements allows for the selection, optimization, and replacement of element materials specifically for the application and process step in case of wear.

More about our process technology

Properties & benefits

Extended processing length
Shear rate variable by machine speed
Increased residence time
Optimized product quality
Low specific energy input

Improved wear-resistant materials
Easy inspection and cleaning
Short changeover times
Rapid installation and commissioning
Processing a wide range of formulations with the same screw configuration

Details regarding manufacturing powder coatings

PCS Co-Kneader seriesThe solution for powder coatings and thermosets

Intense distributive mixing at low temperatures

With its combined screw rotation and axial movement of its Co-Kneader screw, the BUSS Co-Kneader achieves intense distributive mixing which generates extensional flow, a large number of shear interfaces and cross-channel mixing. The melting and mixing energy input is almost exclusively mechanical.

Regular, moderate shear rates

Moderate shear rates enable controlled mixing at low temperatures, whereby only the shearing required for the respective task is applied. Narrow shear rate distribution ensures even shear rates for each individual particle. This results in high-quality preparation with reduced energy expenditure.

Precise temperature control

The BUSS Co-Kneader technology has been well-known for precise temperature control for more than six decades. The controlled energy input is due to uniform shear rates combined with precise temperature monitoring by thermocouples located in pins at any desired position along the process section.

High filler loading can be achieved

High filler loading is enabled via additional inlet openings, split filler material feed, the removal of air inclusions via back venting and excellent transport efficiency. The moderate shear rates allow perfect handling of the highest viscosities for such high filler loading.

Highly wear-resistant materials

Kneading elements and pins from novel tungsten carbide alloys ensure excellent performance for high-wear applications such as EMC. Their service life is considerably longer than that of components made of conventional wear-resistant materials.

PCS brochure download

Further details for thermoset compounding

Efficient service concept

We advise you comprehensively in selecting your most suitable BUSS Co-Kneader, while always remaining flexible and customer-oriented. Thus, we can integrate our PCS Co-Kneader into your existing production plant as an individual unit or also work our way through the entire line with you from pre-mixing to the cooling belt in order to find the ideal individual solution for your needs.

The BUSS service team is available to you worldwide for professional support in handling your compounding system. From project engineering via process support consultation, installation and commissioning, to training and exemplary service, we partner you in securing your long-term investment. This also incorporates retrofitting, overhaul, relocation or modernization of your compounding systems.

Technical data

PCS 30

Throughput rates [kg/h]	up to 40
Feeding Device
Type	Inlet hopper
Hopper Volume [l]	1
Side Feeder Screw Diameters [mm]	-
Drive Rating [kW]	-
BUSS Kneader
Process Length	11 or 14 L/D
Screw Diameter [mm]	30
Screw speed max. [rpm]	500
Heating capacity [kW]	6
Drive rating max. [kW]	5.5

PCS 46

Throughput rates [kg/h]	250
Feeding Device
Type	Inlet hopper
Hopper Volume [l]	3
Side Feeder Screw Diameters [mm]	-
Drive Rating [kW]	-
BUSS Kneader
Process Length	11 or 15 L/D
Screw Diameter [mm]	46
Screw speed max. [rpm]	650
Heating capacity [kW]	2 x 9
Drive rating max. [kW]	30
Dimensions (Explanations Below)
Length (L1) [mm]	2 200
Length (L2) [mm]	3 500
Width (W1) [mm]	600
Width (W2) [mm]	2 200
Height (H1) [mm]	1 200
Height (H2) [mm]	1 500

PCS 70

Throughput rates [kg/h]	700
Feeding Device
Type	Side Feeder
Hopper Volume [l]	50
Side Feeder Screw Diameters [mm]	40
Drive Rating [kW]	1.1
BUSS Kneader
Process Length	11 or 15 L/D
Screw Diameter [mm]	70
Screw speed max. [rpm]	650
Heating capacity [kW]	2 x 12
Drive rating max. [kW]	65
Dimensions (Explanations Below)
Length (L1) [mm]	2 800
Length (L2) [mm]	11 000
Width (W1) [mm]	2 100
Width (W2) [mm]	3 500
Height (H1) [mm]	1 300
Height (H2) [mm]	2 400

PCS 100

Throughput rates [kg/h]	1500
Feeding Device
Type	Side Feeder
Hopper Volume [l]	130
Side Feeder Screw Diameters [mm]	60
Drive Rating [kW]	2.2
BUSS Kneader
Process Length	11 or 15 L/D
Screw Diameter [mm]	100
Screw speed max. [rpm]	650
Heating capacity [kW]	2 x 12
Drive rating max. [kW]	110
Dimensions (Explanations Below)
Length (L1) [mm]	4 500
Length (L2) [mm]	13 500
Width (W1) [mm]	2 700
Width (W2) [mm]	3 600
Height (H1) [mm]	1 500
Height (H2) [mm]	2 900

1 Premix discharge station
2 Side feeder
3 Process section
4 Main drive
5 Heating/cooling units
6 Gear box
7 Cooling rolls
8 Crusher
9 Control cabinet
10 Drive cabinet

More detailsabout BUSS Co-Kneaders PCS 30 and PCS 46

Pilot plant PCS 46 15R

The BUSS Co-Kneader PCS 46 is a versatile, compact small-scale compounder for challenging R&D work and pilot runs. This economical, user-friendly small batch compounder has similar process properties to the large production-scale BUSS Co-Kneaders, with output rates of up to 250 kg/h.

Thanks to the modular processing zone, all production process conditions can be precisely emulated. The split barrel design enables not only optimal access to all process parts, but also the visual assessment of all individual steps along the processing zone.

Laboratory Co-Kneader PCS 30

The BUSS laboratory Co-Kneader PCS 30 is a versatile, compact small-scale compounder for research and development, color matching and customer sample production.

This economical, user-friendly laboratory compounder has similar process properties to the large production scale BUSS Co-Kneaders, with outputs ranging from 300 g for samples up to 40 kg/h. Based on its process scale-up capabilities it is predestined as a universal laboratory compounder offering a high degree of efficiency and flexibility.

Find your individual PCS Co-Kneader configuration with us now

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More about us

PCS Co-Kneader Brochure

All detailed information on our PCS Co-Kneader series summarized in one document. Details in the brochure focus on the processing of powder coatings with our PCS Ko-Kneader series.

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PCS Flyer EMC

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