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Innovative plants by Zeppelin Systems

Innovative plants by Zeppelin Systems

For the plastics industry

Proven technology and experience deliver process competence

We specialize in the design, construction, and technological advancement of plants for producing engineering plastics. Each installation is precisely tailored to your products and requirements. Our core expertise lies in integrating all components for conveying, mixing, dosing, storage, and dust removal into a cohesive system that centers on your high-quality bulk materials. Introducing product into reactors is also well within our capabilities, as we understand the unique demands of engineering plastics. With our extensive, long-standing experience in this sector, you can rely on Zeppelin Systems as your trusted partner. Together, we’ll maximize the performance of your processes—regardless of location and even under the most extreme conditions. Our commitment doesn’t end with plant delivery: we remain available after commissioning for trial runs, training, and service. With our 360° service, you’ll receive professional support at every phase of your project.

Benefits

Our advantages for the industry

1.

Expertise in plant engineering

In addition to complete plants, Zeppelin offers a wide range of pneumatic and hydraulic conveying systems, numerous storage-silo options (Bolt-Tec, Panel-Tec), and diverse process steps (homogenizing, screening, degassing, cooling, etc.).

2.

Global expertise and local presence

Worldwide solutions with local integration—our international footprint supported by offices in over twelve countries.

3.

Decades of experience and implementation

Our expertise encompasses feasibility studies, cost estimates, Front End Engineering Design (FEED), Process Design Packages (PDP), and Basic Design packages. We also offer a wide range of global references for polyolefin plants. Thanks to our extensive know-how in process engineering, sales, and project management through to service, we can implement your plants quickly, safely, and cost-efficiently—and support you throughout the after-sales phase.

Areas of application

Areas of application

Zeppelin Systems covers the entire process chain in the plastics industry—from production through bulk‐material storage and packaging. We are particularly valued for the seamless integration of our systems and components into the overall process. Committed to corporate social responsibility (CSR), we collaborate with certified suppliers and assume responsibility for environmental protection.

Solution Provider

Solution Provider

Thanks to our engineering expertise, we deliver a customized concept precisely tailored to your site and product requirements.

Swift project implementation

Swift project implementation

All commodity-plastics plants benefit from our extensive project-management experience—whether producing packaging materials, molded components for vehicles and computers, construction materials, sports textiles, or medical and hygiene products.

We are problem solvers

We are problem solvers

PA, PC, PS, PLA, PU—or something entirely different? We have the answers to your questions and requirements. With our expertise, we play a vital role in meeting the exacting demands for engineering plastics on behalf of our customers.

Technological innovation

Technological innovation

We offer a broad spectrum of conveying and screening techniques, for example. This not only ensures optimal product handling but also guarantees an exceptionally high degree of purity.

May we assist you in finding the right solution?

Challenges in the manufacturing of engineering plastics

CAPEX in focus



Despite the complex demands of engineering plastics, there is significant potential for savings here as well. The key lies in efficient products and a cost-conscious approach. These foundations are established collaboratively at the very early stage of the project. Thanks to Zeppelin Systems’ outstanding global presence, local resources are leveraged to the fullest—across engineering, procurement, and on-site services.


Low OPEX



Our sophisticated solutions for a variety of products deliver larger batch capacities with the highest quality and low energy consumption. For example, hydraulic conveying ensures low operating costs—saving between 60 % and 80 % of energy costs compared to pneumatic systems. Other methods, such as strand conveying or IntraFlow, enable a significant reduction in gas volumes and, consequently, smaller pipe diameters.


High product quality is achievable



In the manufacture of plastics and in downstream logistics, the product is subjected to mechanical stress. We focus on the quality of the end product and the purity of the bulk material, selecting the optimal process for your product. Our proven sifters effectively remove dust particles, fibers, and ‘angel hair.’ Because engineering plastics can also generate substantial fiber formation, we have developed the VGS and FVS series to reliably separate oversized fibers. For cleaning plastic granules—such as removing fiber nests and strands—we use drum screens. Cyclone separators are employed to separate bulk solids from gas streams, for example in pneumatic conveying systems.


Deep Process Expertise with Attention to Detail



We are highly valued for the seamless integration of our systems and components into the overall process. We develop your entire material supply chain—from raw material to final product—whether it is bagged or shipped in bulk.


Process-Oriented Conveying Technology for Superior Product Quality



Conveying distances of up to 1,000 meters—or even beyond—are not uncommon for both commodity and engineering plastics. Our patented Cyclo Feeder, combined with hydraulic conveying, ensures extremely gentle product handling over such distances, with minimal abrasion or loss.


Tailored Degassing and Mixing Technology



In the world of engineering plastics, process or raw-material fluctuations need not result in variable product quality. We offer process silos for degassing, heating, and cooling, as well as mixers. Our mixing silos compensate for irregularities in good time: from Multi-Pipe and Multi-Channel units for large volumes, to the Multi-Flow version for small batches and technical plastics, and even fluid-bed mixers for bulk solids with particle sizes below 500 μm. Each installation is customized to your product requirements.

Process steps

Description of the process steps in the field of engineering plastic

We support you from the very beginning! Even in the earliest planning phases (FEED, feasibility studies), it’s essential to take into account all market conditions, expansion possibilities, and other contingencies. Leveraging our global experience, we successfully launch even the most complex plants. We design your installation based on factors such as throughput, product quality, degassing processes, mixing, storage, CAPEX, OPEX, and more. With our own high-performance key components—airlocks, diverter valves, sifters, silos, mixers, etc.—you receive a solution or turnkey plant precisely tailored to your needs. In our network of technical centers (among the largest worldwide), we can conduct full-scale (1:1) testing of your products in advance.

Homogenization and degassing

Homogenization and degassing

To compensate for raw-material fluctuations and varying granulate properties—and to achieve consistent product quality—the granulates are mixed or homogenized. This is typically done in homogenizing silos, where recirculation and the specific mixer geometry balance out these variations.

In some processes, it may also be necessary to remove residual monomers (degassing), which takes place in degassing silos. Here, a controlled flow of air is evenly distributed across the silo cone’s cross-section. This strips the residual monomers from the granulate, which are then fed into the regenerative thermal oxidizer (RTO).

Dust removal and cleaning

Dust removal and cleaning

During pneumatic conveying over long distances, the granulate experiences abrasion in the form of dust, fibers, or “angel hair.” For quality reasons, this is unacceptable in the final product. Therefore, this type of abrasion is removed—e.g. in product-cleaning systems or sifters. Ideally, this cleaning always takes place at the end of the material-flow chain, i.e. before loading into containers or silo trucks, or prior to bagging.

Storing

Storing

After homogenization, the granulate is transferred into storage silos for interim holding before being conveyed for bagging or prepared for bulk loading into containers or silo trucks.

Bagging

Bagging

From the storage silos, the granulate is conveyed to the bagging silos—ideally via a sifter—to ensure maximum product quality. From the bagging silos, the granulate is then packed into 25 kg bags using FFS machines, or alternatively into big-bags or octabins.

Services

Discover our comprehensive range of services

Industrial-scale testing

Zeppelin Technical Center

Industrial-scale testing

Testing is good; testing at a 1:1 scale under real-world conditions is even better. To support this, we have established optimal facilities at our Friedrichshafen technical center: based on your recipe and desired throughput, we identify the plant technology tailored to your needs—and test the complete system for you in live operation.

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Automation with foresight

Automation

Automation with foresight

Above all, your plant must do one thing: run and deliver. That’s why we provide you with reliable, professional service. Rely on our global service network for expert consultation and extremely fast spare-parts supply to minimize downtime. When needed, we’re also at your side digitally—from virtual troubleshooting to online-supported commissioning.

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Service without compromise

Service

Service without compromise

In the 21st century, optimization often means automation. We ensure that your automation project is a complete success in terms of both efficiency and cost-effectiveness. To achieve this, we rely on cutting-edge control systems whose open architectures prepare you for the challenges of tomorrow—and beyond.

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Resources

Brochures for download

EXPERIENCE CREATES PROCESS COMPETENCE

EXPERIENCE CREATES PROCESS COMPETENCE

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