Maximum process stability and pellet quality for next-generation production

For decades, MAAG has set benchmarks in underwater strand pelletizing technology (USG). With the new M²-USG generation, the company introduces a system designed to deliver enhanced process stability, higher throughput, and consistently superior pellet quality. Design improvements combined with advanced sensor integration enable customers to achieve more reliable production and improved operational efficiency.

Focus on reliability and product quality  

The new development is engineered to ensure maximum system availability (>99% OEE) and highly stable production processes. Reduced downtime and minimized scrap rates help lower operating costs while improving overall plant profitability.

At the core of the system is the newly developed M²-USG cutting head, designed to simplify operation and maintenance while minimizing the risk of operator error. Maintenance procedures can largely be performed without tools, and cleaning times have been significantly reduced, allowing operators to return to production faster.

From polymer melts to perfect pellets  

MAAG systems are engineered to produce uniform, cylindrical pellets with minimal fines. During the process, the polymer melt passes through a die plate, is cooled and automatically guided into the pelletizer.

Precise control of process parameters is essential. Incorrect settings can cause strand adhesion, unstable cutting conditions, and ultimately production interruptions. The M²-USG addresses these challenges with a series of targeted design optimizations, helping customers maintain stable, efficient, and sustainable production.

Mastering the critical startup phase  

The startup phase is often one of the most critical moments in pelletizing operations. During this stage, polymer strands must be reliably transferred into the guide system.

A newly developed scraper combines high operating speed with particularly gentle strand handling. The strands are cut sequentially at the die plate and fed into the strand guide section and the cutting head with a controlled time delay. This significantly reduces the risk of strand sticking, clogging or excessive startup waste, resulting in faster and more reliable process ramp-up.

Seamless transition for enhanced stability

An optimized water film on the startup table prevents turbulence and reduces the risk of strands sticking together. In addition, transport water is injected immediately after cutting, preventing potential blockages inside the cutting head, even when processing high-temperature polymers or challenging materials such as polycarbonate.

The result is smoother machine operation, improved process stability and increased system availability for the customer.

Larger cutting rotor for higher performance  

The new cutting head features a compact and optimized design with improved sound insulation. The rotor diameter has increased from 162.5 mm to 200 mm, while the number of blades has grown from 30 to 36.

This upgrade enables significantly higher throughput while extending service life by 20%. A stable cutting gap ensures consistently high pellet quality and reduces maintenance requirements and spare-part consumption further lowering operating costs.

High capacity in a compact design  

The M²-USG is available in machine widths of 600, 900, and 1200 mm. At 600 mm width, the system achieves throughputs of up to 13,000 kg/h (PET), while the 1200 mm version reaches up to 24,000 kg/h - significantly exceeding the performance of previous models.

This higher capacity allows processors to achieve the same output with smaller machine sizes, reducing both capital investment and installation footprint.

Integrated sensors for maximum efficiency  

Integrated sensors continuously monitor key parameters such as vibration, temperature, flow rates, and pressure to ensure an optimal production at the sweet spot. Any deviations are immediately detected and reported, also via remote monitoring, helping operators prevent process instability and scrap.

A camera system monitors strand flow, while compressed air consumption is also tracked. In addition, energy-efficient reluctance motors contribute to lower energy consumption and improved sustainability.

Conclusion

With its advanced engineering, improved process stability, and outstanding pellet quality, the new M²-USG sets a new benchmark in underwater pelletizing.

Customers benefit from reduced operating costs, higher throughput, improved efficiency, and integrated sensor technology that ensures maximum process reliability.

In short: The M²-USG demonstrates that even a proven pelletizing system can still be significantly optimized.