The Way Out For The Plastic Industry Under High Standards: Twin-screw Extruder
Introduction: An Urgent Industrial Upgrade
The global plastic industry is standing at a critical crossroads. With increasingly strict environmental regulations, growing consumer demand for sustainable products, and the green requirements of international brand supply chains, plastic granulation production is facing unprecedented challenges of high standards and requirements. From the EU's SUP directive to China's upcoming implementation of 14 national standards for the plastic industry, compliance pressure and market demand are jointly driving a profound industrial transformation. In this context, efficient extruders, especially advanced co rotating twin screw extruders, are transforming from "optional equipment" to "essential cores", becoming a key factor determining whether enterprises can survive and develop in the new era.
1. The severe challenges and difficulties faced by the plastic granulation industry
1.1 Tightening regulatory and standard environment
The plastic granulation industry is being placed under the spotlight of global environmental regulations. Starting from February 1, 2026, China will implement 14 national standards for the plastic industry, covering multiple dimensions such as material properties, testing methods, and environmental requirements. At the same time, international regulations such as the European Union's PPWR have also put forward clear requirements for the recyclable design of plastic products. These standards are not only technical specifications, but also mandatory thresholds for market access. Enterprises that do not meet the standards will face severe consequences such as product delisting, market bans, and even high fines.
1.2 Structural Challenges and Technological Bottlenecks in the Industry
The current plastic granulation industry presents a clear "small and scattered" pattern. According to statistics, there are over 6200 enterprises engaged in waste plastic granulation in China, of which 78% are small enterprises with an annual production capacity of less than 5000 tons. This dispersed industrial structure has led to many problems:
·Outdated equipment level: A large number of enterprises are still using outdated single screw extrusion equipment, lacking online filtration, vacuum devolatilization, and automatic granulation systems
·Unstable product quality: resulting in high ash content, heavy odor, and significant mechanical performance degradation, making it difficult to meet high-end application needs
·Environmental compliance costs rise: New regulations require companies to provide closed-loop wastewater treatment and VOCs collection systems, increasing processing costs by 800-1200 yuan per ton
1.3 Specific technical difficulties in the production process
In the actual production process, plastic granulation enterprises face many specific technical challenges. Taking the production of polypropylene high melting fiber material by Guangdong Petrochemical as an example, there is a risk of entanglement, padding, and even "enema" during the process. During the production transition, the extrusion granulator frequently experienced abnormalities due to process parameter matching and feed fluctuations, resulting in multiple forced shutdowns and restarts. Frequent driving and parking not only disrupt the normal production rhythm, but also cause additional damage to the equipment.
1.4 The pressure brought by the upgrading of market demand
The downstream application market's requirements for plastic particles are also constantly increasing. Driven by the "dual carbon" target and international brand ESG procurement, the market's demand for high-quality and consistent recycled particles is increasing day by day. However, currently less than 15% of regenerated particles can be stably used for high-end spinning processes such as FDY or POY production. Most products can only be used in low tech areas such as carpet fabrics and geotextiles, with limited added value.
2. co-rotating twin screw extruders: the core technology solution for efficient production
2.1 Technical advantages of twin screw extruder
Faced with industry challenges, the co rotating twin screw extruder has become the core solution for upgrading plastic granulation with its excellent performance. Compared with traditional single screw extruders, twin screw extruders have the following significant advantages:
·Higher mixing efficiency: The special screw design enables more thorough melt mixing, ensuring even dispersion of additives
·More precise process control: Multi temperature zone control system and flexible screw combination can accurately regulate process parameters
·Enhanced exhaust volatilization ability: An effective vacuum system can remove volatile substances from materials and improve product purity
·Wide adaptability: The same device can handle multiple formulas, reducing production losses
2.2 Production efficiency improvement brought by efficient extruder
The use of advanced and efficient extruders can bring comprehensive benefits to enterprises. Taking practical application cases as an example, Dongrun Special Rubber and Plastic Co., Ltd. has achieved a 20% to 30% increase in production efficiency, a 5% decrease in electricity consumption, and a significant 50% to 60% reduction in labor costs after introducing a new twin screw extruder.
As a professional manufacturer of plastic polymer blending and modification equipment, Nanjing Kelongwell Chemical Machinery Co., Ltd. has developed a co rotating twin screw extruder that is particularly suitable for production scenarios with high technological requirements such as degradable plastics, modified plastics, and blended plastic modification.
2.3 Technical Characteristics for Dealing with High Standard Production
To meet the increasingly high standards for plastic granulation, modern high-efficiency twin screw extruders integrate multiple advanced technologies:
·Intelligent control system: Real time monitoring and adjustment of process parameters to ensure product quality consistency
·Efficient filtration system: Multi layer filtration design effectively removes impurities, meeting the purity requirements of high-end applications
·Energy saving design: optimized heating and transmission system reduces energy consumption and carbon emissions
·Modular design: easy to clean and maintain, reducing downtime during production changes
2.4 Key question answer: Practical application of twin screw extruder
Q: How to choose a suitable twin screw extruder for international customers who are new to plastic granulation?
A: Firstly, it is necessary to clarify the characteristics of the production materials (such as melt index, thermal sensitivity, etc.) and the quality requirements of the target product. Co directional twin screw extruders are typically suitable for formulations that require thorough mixing and devolatilization, while non directional twin screw extruders are more suitable for heat sensitive materials. Nanjing Kelongwell Chemical Machinery Co., Ltd. provides full technical support from equipment selection to process optimization, helping customers make the best choices.
Q: How can twin screw extruders cope with fluctuations in raw material quality?
A: Modern high-efficiency extruders are equipped with advanced feed control systems and process adaptive technology, which can adjust parameters such as screw speed, temperature, and vacuum degree in real time to offset the impact of raw material quality fluctuations on the final product quality. Especially for scenarios where the consistency of raw materials such as recycled plastics is poor, this adaptability is particularly important.
3. Development directions and strategic suggestions for future plastic granulation
3.1 Technological Upgrade and Intelligent Transformation
The future development of the plastic granulation industry will inevitably move towards intelligence, precision, and green direction. In smart factories, twin screw extruders will operate autonomously through IoT systems, achieving real-time analysis of production data and seamless dialogue between devices. This intelligent transformation can not only improve production efficiency (reportedly up to nearly 30%), but also reduce unplanned downtime through predictive maintenance, ensuring production continuity.
3.2 Circular Economy and High Value Development
With the development of the global circular economy, the plastic granulation industry needs to transform from the traditional "recycling regeneration" model to "high-value applications". This means not only increasing the production of recycled particles, but also improving their quality so that they can be applied in higher value-added fields such as automotive parts, high-end packaging, and electronic products. The new national standards, such as the "Guidelines for Plastic Recyclable Design," and 11 other national standards, will be fully implemented on February 1, 2026, providing a complete technical support system for the design of plastic recyclability.
3.3 International Development Strategy
For plastic granulation enterprises targeting international customers, special attention should be paid to:
·International standard compliance: Ensure that products comply with international standards such as the EU SUP Directive and GRS certification requirements
·Carbon footprint management: Establish product lifecycle carbon footprint data to address potential carbon tariff barriers
·Supply chain transparency: Support supply chain traceability through technologies such as blockchain to meet brand ESG requirements
Nanjing Kelongwell Chemical Machinery Co., Ltd. has exported its products to more than 50 countries including Japan, Indonesia, Malaysia, Singapore, Australia, Dubai, etc. It has accumulated rich experience in the international market and can provide customers with production solutions that meet international standards.
3.4 Sustainable Development and Environmental Compliance
Faced with increasingly strict environmental requirements, plastic granulation enterprises must incorporate environmental compliance into their core strategy:
·Investment in environmental protection facilities: construction of wastewater closed-loop treatment system and VOCs collection device to meet emission requirements
·Energy saving and consumption reduction: Choose production equipment with high energy efficiency, such as high-efficiency twin screw extruders, to reduce energy consumption per unit product
·Process optimization: Reduce waste generation and improve raw material utilization through process innovation
3.5 Key Question Answer: Future Investment and Planning
Q: What are the key recommendations for new investors planning to enter the plastic granulation industry?
A: Firstly, to avoid redundant low-end construction, we should directly target the mid to high end market and invest in advanced equipment such as high-efficiency extruders. Secondly, pay attention to the investment in environmental protection facilities to ensure compliance with environmental requirements from the beginning. Thirdly, consider establishing or connecting stable channels for raw material recycling. Finally, it is recommended to seek cooperation with professional equipment suppliers such as Nanjing Kelongwell Chemical Machinery Co., Ltd. to obtain comprehensive support from equipment to process.
Q: How should existing plastic granulation enterprises cope with the upcoming implementation of the new national standard in 2026?
A: Firstly, conduct a compliance assessment to identify the gaps between existing equipment and processes and the new national standards. Focus on investing in equipment upgrades that can improve product consistency and purity, such as adding vacuum devolatilization systems, optimizing filtration devices, etc. At the same time, strengthen the raw material pretreatment process to ensure the quality of the incoming materials. Considering collaborating with equipment suppliers for targeted transformation, Nanjing Kelongwell Chemical Machinery Co., Ltd. has mature experience in this field.
Conclusion: Embracing the era of high standards with technological innovation
The plastic granulation industry is undergoing a profound transformation from "quantity" to "quality". Faced with constantly improving production standards and environmental requirements worldwide, enterprises can only maintain competitiveness through technological innovation and equipment upgrades. Advanced co rotating twin screw extruders and high-efficiency extruders are not only tools to improve production efficiency, but also key guarantees for enterprises to achieve product upgrades, meet international standards, and expand high-end markets.
Nanjing Kelongwell Chemical Machinery Co., Ltd. is committed to providing customers with efficient plastic extrusion solutions that meet the strictest production standards, based on years of technical accumulation and rich international market experience in the field of plastic polymer blending and modification equipment. In the new era of high standards and high quality in the plastic granulation industry, choosing suitable technology partners and investing in advanced production equipment will be a wise decision for sustainable development of enterprises.
The future belongs to those enterprises that can combine environmental responsibility, technological innovation, and market insights. In the profound transformation of plastic granulation, let us shape the sustainable future of the industry together with efficient, precise, and environmentally friendly production methods.
