New Features for Greater Efficiency and Quality

For decades, Maag has set benchmarks in underwater pelletizing. With the new M²-USG generation, the company now introduces a system that delivers enhanced process stability, increased throughput, and improved pellet quality—thanks to design upgrades and advanced sensor integration.

Focus on Reliability and Product Quality

This new development targets maximum availability (>99% OEE) and stable processes. Reduced downtime and scrap lower production costs and boost profitability. At the heart of the system is the new M²-USG cutting head, which simplifies operation and maintenance while minimizing operator errors. Maintenance is largely tool-free, and cleaning times are significantly reduced.

From Polymer Melt to Perfect Pellets

Maag systems produce uniform, cylindrical pellets with minimal fines. The melt is pushed through a die plate, cooled, and automatically guided into the pelletizer. Precise process parameters are crucial—incorrect settings can cause strand sticking and shutdowns. The M²-USG mitigates these risks through detailed optimizations, ensuring sustainable operation.

Mastering the Critical Startup Phase

During startup, polymer strands are automatically directed to the guide system. A newly developed scraper combines speed with gentle handling: strands are cut sequentially at the die plate and fed into the guide system with a time delay. This significantly reduces the risk of sticking, clogging, or startup waste, enabling faster and more stable process initiation.

Seamless Transition for Enhanced Stability

An optimized water film on the startup table prevents turbulence and strand adhesion. Additionally, transport water is injected immediately after cutting—avoiding blockages in the cutting head, even at high temperatures and with demanding polymers like polycarbonate. The system runs more smoothly and stably, increasing throughput and availability.

Larger Cutting Rotor for Higher Performance

The new cutting head is compact, optimized in design and comes with an improved sound-insulation. The rotor diameter has increased from 162.5 mm to 200 mm, with the number of blades upgraded from 30 to 36. Customers benefit from higher throughput and 20% longer service life. A stable cutting gap ensures consistent pellet quality while reducing maintenance and spare part costs.

High Capacity in a Compact Design

The M²-USG is available in widths of 600, 900, and 1200 mm. At 600 mm, it achieves up to 13’000 kg/h (PET), and up to 24’000 kg/h at 1200 mm—significantly more than previous models. This allows for smaller machine sizes, reducing investment costs and footprint.

Integrated Sensors for Maximum Efficiency

Sensors monitor vibrations, temperatures, flow rates, and pressures to ensure optimal cutting gap. Deviations are reported immediately, even remotely, helping to prevent scrap. A camera monitors strand flow, and compressed air is tracked. Additionally, energy-efficient reluctance motors contribute to further savings.

Conclusion

The new M²-USG leads the field with technical innovations, improved stability, and superior pellet quality. The M²-USG reduces operating costs, increases throughput and efficiency, and offers state-of-the-art sensor technology for maximum process reliability. A clear advancement in underwater pelletizing.

In short: The M²-USG proves that even a well-established pelletizing system can still be optimized.

Polystyrene (PS)

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