trendgineering
Smart retrofit, strong future
| Petra Rehmet
How D PLAST improved production efficiency by upgrading its ZE UTX twin-screw extruder
A modern control system for a proven technology: D PLAST a.s., a Czech specialist in PVC-free compounds for demanding food-contact applications, has successfully modernized its ZE UTX twin-screw extruder in close cooperation with KraussMaffei Extrusion. By upgrading the machine with a state-of-the-art process control system, the company has significantly improved production reliability, process transparency, and long-term serviceability.
Headquartered in Zlín, Czech Republic, D PLAST operates two production sites and employs approximately 140 people. The company has built a strong reputation in the food industry, where strict regulatory requirements and tight quality tolerances require maximum process stability and traceability.
The ZE75Rx46D UTX twin-screw extruder plays a key role in producing high-quality food-grade granulates for global beverage and packaging manufacturers.
Proactive modernization for long-term security
The decision to retrofit the ZE UTX was driven by a proactive strategy. After many years of reliable operation, the original electrical installation and control system had become the most critical element in terms of long-term availability and spare parts security.
While mechanical components had been continuously upgraded, the existing control platform no longer met modern requirements in terms of usability, transparency, and sustainability.
Our commitment is to deliver consistent, repeatable quality under the highest regulatory standards. The retrofit was a proactive step to secure long-term reliability for one of our most important production lines.Jan Kotěna
R&D Manager D PLAST
Smooth execution and fast commissioning
The retrofit was prepared in detail and executed in close coordination between both teams. Thanks to thorough planning and clear alignment of technical interfaces, the project progressed smoothly and the line was commissioned ahead of schedule.
Beyond technical expertise, the partnership itself proved to be a key success factor.
What we particularly value in working with KraussMaffei Extrusion is the fairness and transparency at every level. What was promised was delivered, and any limitations were communicated openly and in time. In our view, long-term partnerships are built not only on price, but on reliability, competence and mutual trust.Jan Kotěna
R&D Manager D PLAST
Enhanced performance, increased stability
With the new machine control system in place, D PLAST now benefits from a modern, intuitive operating platform aligned with today’s twin-screw extruder standards.
The upgrade enhances process monitoring and control, reduces the risk of unexpected failures, and improves long-term availability of spare parts and service support.
Overall, the retrofit provides greater operational stability and secures the performance of a key production asset for years to come.
The project highlights the extensive scope of our retrofit solutions, allowing existing systems to be comprehensively modernized and adapted to current technological standards. This offers a cost-efficient alternative to new investments while maximizing asset value.Sven Plattner
Head of Retrofit KraussMaffei Extrusion
Building on a long-standing partnership
The success of the retrofit has already laid the foundation for further joint projects. Building on the positive experience, D PLAST and KraussMaffei Extrusion are currently preparing additional investments to expand technological capabilities and strengthen competitiveness in global markets.
As Jan Kotěna emphasizes, these next steps would not have been possible without the successful modernization of the ZE UTX demonstrating how a well-executed retrofit can unlock long-term value far beyond the initial upgrade.
