SCREENING · MICRO + MINI
Hybrid ZE 5/9
The lowest-material entry point. Run at 5 mm, then step to 9 mm when a formulation earns more material.
- Diameters
- 5 / 9 mm
- Max torque
- 2.5 / 14.5 Nm
- Volume class
- Micro + Mini
- Best for
- Pharma, new polymers
01 / 07 — TWIN-SCREW MICRO COMPOUNDERS · CONTINUOUS AND BATCH · FROM 1 GRAM
Compound a new formulation from a single gram. Scale it on the same bench.
Parallel co-rotating twin-screw micro compounders built by Three-Tec GmbH—with application engineering, installation, and trials from our Piscataway, New Jersey lab. Run continuously, or add the recirculation channel for a timed batch workflow.
Ø 5 mm
2.5 Nm
Ø 9 mm
14.5 Nm
Ø 12 mm
20 Nm
1 g
Minimum starting batch at 5 mm
1.2 cm³
5 mm empty volume at L/D 15:1
0.7–0.8 g
Typical recovery from a 1 g charge
2 modes
Continuous and timed batch
02 / 07 — START WITH THE JOB
Which micro compounder fits your work?
Most laboratories buy for one of three jobs. Start with the material, output, and amount available—not a model number.
03 / 07 — THE LINEUP
Choose by batch volume.
Three volume classes are set by screw diameter. Each Hybrid carries two of them on one table-top frame, so one instrument covers two development stages and switches between them in minutes.
MICRO · Ø 5 mm
1.2 cm³
Free volume at L/D 15:1. Charges from 1 gram for APIs, newly synthesized polymers, and costly additives.
MINI · Ø 9 mm
14.5 Nm
Mid-range formulation work with more torque for viscous melts. Free volume is confirmed during configuration.
LAB · Ø 12 mm
20 Nm
Filled and fiber-reinforced compounds, plus enough material for molding and testing. Free volume is confirmed during configuration.
| Model | Micro · 5 mm | Mini · 9 mm | Lab · 12 mm |
|---|---|---|---|
| Hybrid ZE 5/9 | ● | ● | — |
| Hybrid ZE 5/12 | ● | — | ● |
| Hybrid ZE 9/12 | — | ● | ● |
| ZE12 Compounding Line | — | — | ● |
The configurations
SCREEN-TO-SAMPLE · MICRO + LAB
Hybrid ZE 5/12
The widest span on one frame: 1-gram screening plus the 12 mm torque needed for useful sample quantities.
- Diameters
- 5 / 12 mm
- Max torque
- 2.5 / 20 Nm
- Volume class
- Micro + Lab
- Best for
- Polymer R&D labs
HIGH-TORQUE · MINI + LAB
Hybrid ZE 9/12
For filled and viscous systems where the lab does not need to operate below the 9 mm scale.
- Diameters
- 9 / 12 mm
- Max torque
- 14.5 / 20 Nm
- Side feeder
- Optional
- Volume class
- Mini + Lab
FIBER & FILLER PACKAGE
ZE12 Compounding Line
A long-L/D ZE12 with gravimetric feeding, optional side feeding, and pelletizing for fiber and highly filled systems.
- Torque / pressure
- 20 Nm / 250 bar
- L/D
- Up to 40:1
- Feeding
- ZD 9 FB + side feeder
- Output
- 0.5–10 mm pellets
Shared across every configuration
- Screw design
- Parallel co-rotating screws; modular conveying, reverse, kneading, and mixing elements
- Operating modes
- Continuous, or timed batch mixing with the optional recirculation channel
- L/D ratio
- 15:1 to 40:1, modular
- Temperature
- 230 °C standard; 400 °C option for high-performance polymers
- Cooling
- Water, air, or liquid nitrogen by zone
- Control and data
- Siemens S7-1500, touchscreen HMI, live process values, and CSV export
- Contact surfaces
- 316L stainless steel, Ra 0.8 µm; tri-clamp barrel access
- Compliance options
- cGMP design, 21 CFR Part 11, and ATEX on request
04 / 07 — FINISH THE SAMPLE
Choose the form you need to test.
Every compounder can be configured as a complete line around the sample your laboratory actually needs.
Granules
Strand pelletizing or hot die-face cutting for 0.5–10 mm pellets, including brittle and highly filled melts.
Film
Slit die, film-roll calibration, and tension-controlled winding for cast-film screening.
Fiber and filament
Mono- and multifilament spinning, cooling bath, and winding—including 3D-printing filament.
Test specimens
Prepare compounded material for downstream molding and standardized mechanical testing.
05 / 07 — HOW IT DIFFERS
Batch or continuous? You do not have to choose.
Add the recirculation channel for the timed batch workflow laboratories already know. Open it and the same machine runs continuously with the screw geometry and feeding approach that transfer to larger production extrusion.
| Question | Xceptional / Three-Tec | Typical batch-only unit |
|---|---|---|
| Batch mode, set mixing time | Yes—with the optional recirculation channel | Yes |
| Continuous mode | Yes—parallel co-rotating screws | No |
| Screw configuration | Modular elements arranged for the formulation | Typically a fixed screw profile |
| Scale-up path | Same element concept from 5 mm to production sizes | Transfer to a different machine type |
| Feeding | Gravimetric micro-feeding and optional side feeding | Manual charge |
| Two screw sizes, one frame | Yes—Hybrid configurations | No |
06 / 07 — APPLICATIONS & PROOF
What laboratories compound on it.
Fiber-reinforced and filled plastics
Chopped glass and carbon fiber, minerals, and flame retardants at high loading.
Nanocomposites and masterbatch
Disperse expensive additives in gram quantities before committing kilograms of material.
Biopolymers and recycled blends
Evaluate heat-sensitive materials with short residence times and independent thermal zones.
Battery electrode materials
Continuous mixing of active material, binder, and conductive additive for dry and wet research.
Ceramic and metal feedstocks
Develop highly filled injection-molding feedstocks with controlled feeding and mixing.
Pharmaceutical solid dispersions
Screen amorphous dispersions and implant formulations from limited API quantities.
07 / 07 — TRY IT ON YOUR MATERIAL
Send your formulation. Get compounded material and the data behind it.
Our Piscataway laboratory can begin with limited material. Attend onsite, join by video, or let our team run the agreed plan and send the results.
- Parameter log covering temperatures, torque, and feed rate
- Compounded samples as granules, film, or fiber
- Recommended compounder and downstream configuration
- Optional characterization confirmed during scoping
Micro compounder FAQ
Questions before a material trial.
What is a micro compounder?
A bench-top twin-screw machine that melt-mixes polymers with additives, fillers, or active ingredients in small quantities for formulation development. This platform can operate continuously or in timed batch recirculation mode.
How much material do I need for one run?
The 5 mm configuration can begin from 1 gram. Practical material requirements depend on density, feeding behavior, stabilization, recovery, and the sample quantity needed for testing.
Can it run in batch mode like a recirculating micro compounder?
Yes. With the optional recirculation channel, the melt circulates for a mixing time you set and then discharges. With the channel open, the same machine runs continuously.
Can I change screw diameter on the same machine?
Yes. Each Hybrid configuration carries two diameters—5/9, 5/12, or 9/12 mm—on one table-top frame with shared controls and supporting components.
Can it compound glass or carbon fiber?
Yes. A 12 mm configuration can be equipped with side feeding for chopped fiber and filler. A material trial is recommended to confirm loading, feed behavior, dispersion, and fiber-length goals.
Who supports the system in North America?
Xceptional Instruments provides application engineering, trials, installation, training, and service from Piscataway, New Jersey. Three-Tec GmbH builds the equipment in Seon, Switzerland.