Current Dynamics in The Global Plastic Extrusion Machinery Industry (2025)

1. Market Scale & Momentum

Global revenue reached USD 7.45 billion in 2024 and is projected to increase to USD 7.80 billion by the end of 2025, placing the industry on a 4.7% CAGR path toward USD 12.34 billion by 2035. Growth in the second half of 2025 is currently outpacing first-half projections by 90 basis points (5.3% vs. 4.4%), indicating a strengthening demand environment.

2. Technology Front-Runners

• Twin-screw dominance – This category of machinery is expected to account for 42.6% of 2025 shipments due to its superior mixing capabilities, high throughput, and efficient processing of recycled or highly-filled compounds.  
• AI & IIoT integration – Leading suppliers in North America and Europe are incorporating AI-driven predictive maintenance, real-time quality monitoring, and digital twin simulations, which have been shown to reduce unplanned downtime and scrap rates by double-digit percentages.  
• Energy-efficient designs – Hybrid electric drives and advanced thermal management systems are increasingly replacing traditional hydraulic systems, reducing energy consumption by 15–25% and enabling manufacturers to meet more stringent ESG requirements.

3. Sustainability as a Commercial Imperative

• Recycled and bio-based materials – The introduction of JianTai’s new 500 kg/h recycled-plastic line, Rajoo’s relEX 4.0 blown-film system, and the development of over 3,000 extruders in Europe specifically engineered for compostable resins demonstrate that environmentally friendly configurations have transitioned from niche offerings to mainstream solutions.  
• Regulatory drivers – Extended Producer Responsibility (EPR) laws, plastic taxes, and commitments by brand owners are compelling converters to invest in machinery capable of processing at least 30% post-consumer reclaimed materials without compromising optical or mechanical properties.

4. End-Use Hotspots

Packaging remains the largest application segment, accounting for 36.8% of 2025 demand, driven by the growing adoption of flexible mono-material films, recyclable stand-up pouches, and lightweight trays for e-commerce packaging. The construction sector (pipes, window profiles, WPC decking) and the automotive industry (lightweight bumper beams, EV battery enclosures) follow as the next fastest-growing end-use markets.

5. Competitive Landscape Developments

• Industry consolidation – Pexco’s acquisition of Wisconsin Plastic Products in 2024 has expanded its co-extrusion and complex-profile manufacturing capabilities in North America.  
• Strategic R&D partnerships – European resin producers have established 15 joint R&D centers with machinery OEMs focused on improving the processability of bio-polymers, while modular “plug-and-play” retrofit kits enable mid-tier manufacturers to adopt Industry 4.0 technologies without replacing entire production lines.

6. Outlook for the Next 12–24 Months

The industry is expected to place greater emphasis on integrated turnkey solutions that combine high-output twin-screw platforms, AI-based process control systems, and closed-loop recycling of in-house waste materials. Brazil (6.2% CAGR) and India (5.6% CAGR) are anticipated to emerge as the fastest-growing national markets, fueled by rising infrastructure investments and expanding consumer goods demand.