Twin Screw Extruders Market By Product Type (Co-rotating, Counter-rotating, Others); By Application (Plastics & Polymers, Food & Feed, Pharmaceuticals, Chemicals, Others); By End User (Plastic & Rubber, Food & Beverage, Pharma, Chemicals, Research); By Region (North America, Europe, Asia-Pacific, Latin America, Middle East & Africa), Segment Revenue Estimation, Forecast, 2024–2030

Introduction And Strategic Context

The Global Twin Screw Extruders Market is witnessing robust expansion in 2024, driven by increasing demand for high-performance material processing across industries such as plastics, food processing, pharmaceuticals, and chemicals . Twin screw extruders are industrial machines used for compounding, mixing, and shaping raw materials into finished or semi-finished products, especially in applications requiring precise control over shear, temperature, and pressure. Unlike single-screw systems, twin screw extruders offer superior mixing efficiency , process flexibility , and throughput capability , making them indispensable in advanced manufacturing.

 

As of 2024 , the global market for twin screw extruders is estimated to be valued at USD 1.85 billion . The market is projected to reach USD 2.78 billion by 2030 , growing at a compound annual growth rate (CAGR) of 6.9% over the forecast period.

 

This growth trajectory is underpinned by several macroeconomic and technological trends:

• Industrial automation and smart manufacturing are catalyzing the adoption of digitally controlled extrusion systems for enhanced throughput and reduced downtime.

• The booming plastics and polymer industries , especially in Asia-Pacific and North America, are increasing the need for customized and high-throughput extrusion equipment.

• Rising demand for bio-based and recyclable materials has intensified the need for flexible extruder configurations, favoring twin screw over single screw systems.

• In the food industry , twin screw extruders are increasingly used to manufacture snacks, textured proteins, and pet food due to their ability to handle complex formulations.

• In pharmaceuticals, the adoption of continuous manufacturing methods using twin screw extrusion for drug development and production is on the rise.
   

From a strategic stakeholder perspective, the market brings together:

• OEMs and equipment manufacturers like Coperion , KraussMaffei , and Thermo Fisher Scientific

• Process industries (plastics, chemical, food, pharma)

• R&D labs and academia , exploring advanced compounding techniques

• Government regulators , promoting sustainable and energy-efficient technologies

• Investors , targeting capital equipment firms benefitting from automation and high-margin industrial growth

“As sustainability and material efficiency take center stage, twin screw extrusion is not just a machinery upgrade—it’s becoming a process transformation lever,” notes a 2023 technical brief by the European Plastics Converters Association.

The market's strategic relevance is further amplified by its ability to reduce waste, improve product consistency , and support the shift toward circular economy manufacturing practices. With rising global emphasis on reducing carbon emissions and improving energy efficiency, twin screw extruders are positioned as vital equipment in the transition to greener industrial ecosystems .

 

Market Segmentation And Forecast Scope

To effectively evaluate growth trends and investment hotspots within the Global Twin Screw Extruders Market , the market is segmented based on product type , application , end user , and region . These dimensions allow us to uncover emerging trends, assess demand patterns, and identify high-growth sub-markets.

By Product Type

• Co-rotating Twin Screw Extruders

• Counter-rotating Twin Screw Extruders

• Others (e.g., Intermeshing/Non-intermeshing variants)

Co-rotating twin screw extruders dominate the global market due to their superior mixing capability and efficiency in dispersing fillers, pigments, and additives. These systems are widely used in polymer compounding and food extrusion due to their ability to deliver uniform output. In 2024 , this sub-segment is estimated to hold over 55% of the market share, with strong momentum anticipated in the plastics and chemicals industry.

Counter-rotating extruders , although smaller in share, are gaining interest in PVC and profile extrusion applications , particularly in Europe and Southeast Asia.

 

By Application

• Plastics & Polymers Processing

• Food & Feed Extrusion

• Pharmaceutical Processing

• Chemical Processing

• Others (e.g., Recycling, Biomaterials, etc.)

The plastics & polymers segment remains the largest contributor to revenue, driven by consistent demand for engineered plastics, masterbatches , and thermoplastic composites. However, the food & feed extrusion segment is forecast to grow the fastest, propelled by the rising adoption of twin screw technology in plant-based protein and specialty snack production .

“Advanced extrusion lines in food processing offer higher product integrity and allow cleaner-label formulations, aligning with consumer demand,” notes a 2024 commentary from the Global Food Innovation Network.

 

By End User

• Plastic & Rubber Manufacturers

• Food & Beverage Companies

• Pharmaceutical Companies

• Chemical Processing Units

• Academic & Research Institutions

Plastic and rubber manufacturers are currently the largest adopters of twin screw extruders due to the high throughput needs of the industry and ongoing trends in compounding innovation. Meanwhile, pharmaceutical companies are increasingly integrating twin screw extrusion in continuous drug manufacturing workflows, making this a high-growth vertical in the next decade.

 

By Region

• North America

• Europe

• Asia-Pacific

• Latin America

• Middle East & Africa (MEA)

Among regions, Asia-Pacific leads the market in 2024 with over 38% share , driven by the booming manufacturing sector in China, India, South Korea, and Japan . However, North America is expected to witness strong CAGR due to the growing uptake of automated extrusion lines and the FDA's support for continuous pharmaceutical manufacturing .

 

Market Trends And Innovation Landscape

The twin screw extruders market is undergoing a phase of technological acceleration, fueled by growing demands for material customization , process efficiency , and sustainability compliance . Key players are investing heavily in digital integration , modular designs , and energy-efficient extruder solutions to meet the evolving expectations of end-use industries such as plastics, pharma, and food.

Digitalization and Process Automation

One of the most significant trends shaping the market is the integration of Industry 4.0 technologies into extrusion systems. Twin screw extruders are increasingly being equipped with IoT sensors , real-time analytics dashboards , and remote diagnostics to ensure predictive maintenance and improve process reliability.

“Data-driven extrusion monitoring is reducing downtime by up to 25%, while simultaneously improving output consistency,” noted a 2023 technical case study by Coperion GmbH.

These intelligent systems enable operators to adjust torque, speed, and temperature dynamically , enhancing the quality and repeatability of the output across multiple batches.

 

Rising Use of Twin Screw Extruders in Continuous Manufacturing (Pharma & Food)

The pharmaceutical sector has begun a gradual shift from batch to continuous manufacturing , and twin screw extrusion is central to this transformation. Companies such as Thermo Fisher Scientific and Leistritz have developed lab-scale extruders that support formulation development for solubility-enhancing solid dispersions , especially for poorly soluble drugs.

Likewise, in the food sector, extruders are being customized to handle plant-based protein structures , enabling manufacturers to cater to rising demand for meat alternatives and functional snacks .

“Twin screw extrusion is now a core technology in food innovation labs focused on clean-label and nutrient-dense products,” according to a 2024 report from the European Institute of Food Processing.

 

Materials Science and Biodegradable Polymers

There is also a notable push toward extruders that can efficiently process biodegradable polymers , bio-based compounds , and recycled materials . As environmental regulations tighten, manufacturers are upgrading extruder configurations with corrosion-resistant barrels , vacuum venting systems , and multi-feed hoppers to improve adaptability for novel materials.

Custom screw elements and wear-resistant materials are also gaining popularity to extend operational life and reduce maintenance intervals.

 

Modular and Custom Configurations

The demand for modular extruder designs is rising as manufacturers seek greater flexibility and the ability to upgrade or repurpose their equipment with minimal downtime. Modular twin screw extruders allow changes in screw geometry , barrel setup , and feeder location —enabling users to switch between different material systems or processes efficiently.

 

M&A and Strategic Technology Partnerships

Recent years have seen a flurry of strategic collaborations:

• Clextral partnered with INRAe (France’s National Research Institute) in 2023 to develop new applications for extruded cereal-based proteins .

• Bühler Group collaborated with the Institute of Food Technologists (IFT) to promote extrusion-based food innovation in emerging economies .

• Thermo Fisher expanded its extrusion and granulation technology portfolio in 2024 by launching customizable extruders for research and scale-up.

These partnerships reflect the broader trend of convergence between academic research, automation vendors , and end-use manufacturers .

 

Competitive Intelligence And Benchmarking

The twin screw extruders market is moderately consolidated, with a blend of global technology leaders , regional specialists , and sector-focused OEMs . Key players are competing through a mix of process innovation , tailored application solutions , and global distribution footprints . The race to develop energy-efficient , digitally integrated , and material-flexible extruder systems is intensifying, especially across plastic compounding , pharmaceutical , and food processing domains.

Key Players in the Market

Coperion GmbH
A global pioneer in compounding and extrusion technologies, Coperion offers high-performance co-rotating extruders used extensively in polymer processing and chemical applications . The company is known for its ZSK series, which integrates advanced automation and throughput optimization. Coperion maintains strong market presence across Europe, North America, and China , and focuses heavily on process customization and modularity .

 

Thermo Fisher Scientific
A leading innovator in pharmaceutical twin screw extrusion , Thermo Fisher offers scalable systems for hot melt extrusion (HME) and continuous drug manufacturing . It provides laboratory-scale extruders for formulation development as well as GMP-compliant units for production environments. Thermo Fisher’s edge lies in its integration of real-time analytics and PAT (Process Analytical Technology) .

 

Leistritz AG
Leistritz specializes in medical-grade extruders , particularly suited for oral solid dosage (OSD) forms in drug manufacturing. Its twin screw platforms support continuous granulation and melt extrusion , positioning the company as a key partner in pharma R&D. Leistritz is also expanding into food and biodegradable polymer processing .

 

Bühler Group
Dominant in food and feed extrusion , Bühler has established itself as a key solution provider for cereal, snack, and protein extrusion . The company partners with institutions and startups to accelerate sustainable food development, particularly in plant-based meat and functional food categories. Bühler’s systems are also known for energy efficiency and hygienic design .

 

JSW (The Japan Steel Works, Ltd.)
JSW delivers a comprehensive range of twin screw extruders used in plastics, specialty materials, and chemicals . The company leverages its expertise in screw configuration optimization , ensuring robust performance in high-viscosity and filled materials . JSW continues to expand its reach in Southeast Asia and North America , driven by demand for compounding solutions.

 

KraussMaffei Group
A key player in the plastics and rubber segment , KraussMaffei offers extrusion systems designed for PVC processing, technical polymers , and recycling applications . The firm has invested in digital extrusion platforms that combine machine learning and real-time monitoring for predictive maintenance.

 

Xtrutech Ltd .
Based in the UK, Xtrutech is a niche provider of small- to mid-size extruders tailored for lab, pilot, and specialty applications . The company is known for its fast customization cycles and process-specific screw design services , making it popular among research institutions and formulation labs .

 

Regional Landscape And Adoption Outlook

The adoption of twin screw extruders varies considerably across regions, shaped by differences in industrial maturity , regulatory frameworks , sustainability goals , and sector-specific demand . In 2024, Asia-Pacific leads in both volume and revenue, while North America and Europe remain centers of innovation, particularly in pharmaceutical and food-grade extrusion technologies . Emerging markets in Latin America and the Middle East & Africa (MEA) are gaining traction due to rising investments in plastics and food infrastructure.

North America

The U.S. and Canada are at the forefront of adopting continuous manufacturing technologies , especially in the pharmaceutical and specialty plastics sectors. The FDA's endorsement of continuous drug manufacturing methods has accelerated the use of twin screw extruders in oral solid dosage production.

The region also exhibits growing interest in circular economy practices , with manufacturers deploying advanced extruders to process recycled plastics and biodegradable polymers . Key OEMs such as Thermo Fisher Scientific , Leistritz , and KraussMaffei have well-established operations here, offering both turnkey solutions and after-sales services.

“Twin screw extrusion is now a cornerstone of smart manufacturing initiatives in high-performance polymer and drug development labs across North America,” noted a 2024 whitepaper from the U.S. Pharmacopeia.

 

Europe

Europe has emerged as a regulatory-driven market , particularly in food and chemical processing applications. Strict EU rules on additive dispersion , material recyclability , and hygienic equipment design have pushed manufacturers to adopt high-precision, energy-efficient extruders .

Countries like Germany , France , and Switzerland are innovation hubs, with OEMs like Bühler , Coperion , and Leistritz supporting not only industry but also academic and public-private R&D programs .

Moreover, EU sustainability directives (such as the EU Green Deal) are promoting the use of extruders in bio-compounding and advanced polymer recycling , presenting new avenues for equipment makers.

 

Asia-Pacific

In terms of volume, Asia-Pacific dominates the global market in 2024 with an estimated 38%+ market share , led by China, India, South Korea, and Japan . This is driven by the presence of large-scale plastics and food processing industries , along with aggressive infrastructure development in chemical manufacturing zones.

• China remains the largest manufacturer and user of twin screw extruders, supported by domestic OEMs and cost-competitive suppliers.

• India is seeing a surge in demand from plastic packaging and food extrusion sectors, where modular and medium-capacity extruders are gaining popularity.

• Japan and South Korea are investing in pharmaceutical-grade extrusion and precision compounding systems, often in partnership with Western OEMs.

“High-volume production combined with rising standards of automation is reshaping extrusion markets across APAC,” according to a 2024 report from the Japan Society of Polymer Processing.

 

Latin America

While still developing, Latin America —especially Brazil and Mexico —shows promise due to the growth of consumer goods , food processing , and packaging industries. Regional adoption is largely centered on mid-range co-rotating extruders , with demand focused on cost-effectiveness and multi-purpose capabilities .

Import dependency remains high, with European and Asian OEMs catering to local players via distributors. Governments are beginning to explore incentives for local manufacturing and technological upgrades in plastics recycling.

 

Middle East & Africa (MEA)

MEA is currently an underserved market but holds latent potential , especially in food extrusion, PVC piping, and pharma packaging . The UAE, Saudi Arabia , and South Africa are leading adoption due to investments in industrial diversification and healthcare infrastructure .

Regional constraints include low awareness , high upfront costs , and limited technical support , though these are gradually being addressed through training partnerships and OEM-driven pilot projects .

 

End-User Dynamics And Use Case

The adoption of twin screw extruders varies across end-user industries, with each vertical leveraging the technology for customized processing needs , regulatory compliance , and cost-performance optimization . As automation and sustainability reshape operational priorities, end-users are upgrading from legacy single-screw systems to twin screw platforms that offer superior control, efficiency, and product consistency .

Key End-User Segments

Plastic & Rubber Manufacturers

These manufacturers form the largest end-user group , accounting for a dominant share of global revenue. Twin screw extruders are essential in masterbatch production , polymer compounding , fiber processing , and thermoplastic elastomer blending . The sector values:

• High output capacity

• Material compatibility (e.g., fillers, fibers, colorants)

• Flexibility in screw design for diverse polymers

Leading firms are increasingly automating extrusion lines to improve batch traceability and downtime reduction .

 

Food & Beverage Companies

In the food sector, twin screw extruders enable the production of textured vegetable proteins (TVP) , nutraceutical snacks , breakfast cereals , and pet food . These extruders are preferred for their ability to handle complex recipes while preserving nutrient content and shape fidelity .

The growing consumer demand for clean-label , plant-based , and high-protein formulations is accelerating investment in food-grade extruders, particularly in Asia-Pacific, Europe, and Latin America .

 

Pharmaceutical Companies

Pharmaceutical manufacturers are increasingly adopting continuous manufacturing platforms , with twin screw extruders at the core of:

• Hot Melt Extrusion (HME) for solid dispersion

• Twin-screw granulation for oral dosage forms

• Drug-device combination manufacturing

These systems are integrated with PAT tools , ensuring compliance with FDA and EMA quality standards . The ability to scale from lab to production using consistent screw configurations makes twin screw extrusion ideal for formulation development.

 

Chemical Processing Units

Chemical producers employ twin screw extruders for reaction extrusion , additive dispersion , and advanced material development (e.g., nanocomposites). The demand is driven by:

• High-temperature and high-torque requirements

• Need for venting, dosing, and pressure control

• Compatibility with abrasive or corrosive materials

This segment typically favors robust, modular designs to manage continuous production and high uptime.

 

Academic & Research Institutions

Universities, government labs, and innovation centers use lab-scale twin screw extruders to:

• Prototype novel polymer blends

• Study drug-polymer interactions

• Simulate industrial food extrusion

These users prefer bench-top extruders with flexible configurations, minimal space requirements, and advanced control interfaces.

 

Realistic Use Case Scenario

In 2023, a tertiary research hospital in South Korea integrated a pilot-scale twin screw extruder to develop oral solid dosage forms for oncology drugs with poor solubility. By using hot melt extrusion (HME), the hospital's pharmaceutical division successfully formulated a stable amorphous dispersion with improved bioavailability, reducing drug development time by nearly 30%. The extruder was equipped with in-line Raman spectroscopy to monitor polymer-drug miscibility in real time, ensuring formulation accuracy and regulatory traceability.

This scenario highlights how twin screw extruders are becoming central to advanced drug development , especially in settings prioritizing speed, scalability, and patient-centered innovation .

 

Recent Developments + Opportunities & Restraints

Recent Developments (2023–2024)

• Thermo Fisher Scientific launched a next-gen pharma extruder (Feb 2024 )
  Introduced a GMP-compliant continuous extrusion system integrated with real-time PAT tools for formulation development in oral drug delivery, supporting global regulatory standards.

• Bühler Group unveiled its Modular TX Series for food processing (Oct 2023 )
  The TX Series features energy-optimized drive systems and modular barrels aimed at improving throughput for plant-based meat and cereal products .

• Coperion expanded its Shanghai facility (Aug 2023 )
  The facility will support the rising demand in Asia-Pacific for high-capacity polymer compounding extruders with localized service and training hubs.

• Leistritz formed a joint development project with a European biotech consortium (Dec 2023 )
  The focus is on creating extruded biodegradable delivery systems for vaccines and oral biologics, accelerating pharma-grade extrusion innovation.

• KraussMaffei introduced a digital twin platform for extruders (Jan 2024 )
  This platform enables predictive performance simulation and virtual commissioning , reducing time-to-operation for new manufacturing lines.

 

Opportunities

• Expansion in Pharma Continuous Manufacturing
  Twin screw extrusion is gaining global momentum as regulators like the FDA and EMA push for quality-by-design ( QbD ) manufacturing in pharma. The need for consistent, scalable drug formulation opens vast opportunities.

• Sustainable Plastic and Bio-Compounding Markets
  Growing pressure to process biodegradable and recycled plastics is driving OEMs to develop extruders tailored for green materials , especially in Europe and India.

• Food Security and Functional Nutrition Trends
  Rising demand for textured proteins, fortified snacks, and infant food in emerging markets is expanding the use of extruders in high-volume, clean-label food production.

 

Restraints

• High Capital and Operating Costs
  Industrial twin screw extruders involve significant upfront investment and require skilled operators . For SMEs and processors in developing regions, this remains a barrier to adoption.

• Regulatory Complexity in Pharma and Food
  Compliance with cGMP, HACCP, and EU/US regulatory norms adds complexity to equipment design and validation, slowing down implementation in some segments.
   

7.1. Report Coverage Table

Report Attribute	Details
Forecast Period	2024 – 2030
Market Size in 2024	USD 1.85 Billion
Revenue Forecast in 2030	USD 2.78 Billion
Overall Growth Rate	CAGR of 6.9% (2024 – 2030)
Base Year for Estimation	2024
Historical Data	2019 – 2023
Unit	USD Million, CAGR (2024 – 2030)
Segmentation	By Product Type, By Application, By End User, By Region
By Product Type	Co-rotating, Counter-rotating, Others
By Application	Plastics & Polymers, Food & Feed, Pharmaceuticals, Chemicals, Others
By End User	Plastic & Rubber Manufacturers, Food & Beverage Companies, Pharmaceutical Companies, Chemical Processors, Research Institutions
By Region	North America, Europe, Asia-Pacific, Latin America, Middle East & Africa
Country Scope	U.S., Germany, China, India, Japan, Brazil, South Korea, etc.
Market Drivers	- Surge in demand for advanced polymer compounding - Growth in continuous manufacturing in pharma & food - Shift toward sustainable materials and recycling
Customization Option	Available upon request