All you need to know about twin screw extruders│Twin Screw Hub

Boost Your Productivity
by Up to2x*
Transform Plastic
Processing Efficiency
Twin-Screw Extruders:

Eliminate productionbottlenecks and significantly increase throughput volume
with CTE’s advanced twin-screw extruder technology.
If you're a factory manager seeking to improve profitability, now is the ideal time to invest in next-generation extrusion equipment.
*The comparison of throughput between non-intermeshing, counter-rotating twin-screw extruders and intermeshing, co-rotating types. Based on CTE data (screw diameter: 40mm).
This site is operated by Zenken Corporation and sponsored by CTE Corporation.
INDEX

Double Your throughput volume
in the Same Time

To improve manufacturing efficiency,
the quickest path is to reassess the type of extruder currently in use.
Twin-screw extruders come in various types depending on the screw’s “rotation direction” and “engagement method.”
Among them, the “counter-rotating, non-intermeshing type”offers excellent compounding performance and stable, high-throughput volume —while maintaining operability comparableto conventional systems.
Here’s why counter-rotating, non-intermeshing twin-screw extruders significantly boost productivity
*Based on comparison of throughput between non-intermeshing, counter-rotating and intermeshing, co-rotating twin-screw extruders (screw diameter: 40 mm, data provided by CTE).
Increased raw material volume and rpm

Easier gas venting enables greater
raw material input

In an intermeshing, co-rotating extruder, air and gas are blocked at the kneading disc section,causing a feed-neck phenomenon—a condition where gases generated during melt blending flow back into the feed zone.As a result, material cannot be fed smoothly.

In contrast, a non-intermeshing extruder does not use kneading discs, but instead kneads material between the rotating rotor and the cylinder wall. This structure allows air pathways to form,enabling gases to vent smoothly through the exhaust port.This suppresses backflow, prevents clogging, and ensures stable feeding of high material volumes.

Lower heat generation during kneading eliminates the need to lower
screw speed.

In an intermeshing extruder, material is forced into the narrow kneading disc section, where high shear force is applied.This generates frictional heat, causing the resin temperature to rise rapidly.To avoid thermal degradation, the screw speed must be reduced, which in turn lowers the throughput volume.

In contrast, a non-intermeshing extruder uses a rotor instead of kneading discs to process the material.This grinding-like process reduces localized shear and significantly lowers heat generation.As a result, there is no need to reduce screw speed due to heat concerns, enabling continuous high-speed operation.

Built for Degassing, Conveying,
and Compounding:
The Twin-Screw extruder
Driving a Manufacturing Revolution
CTE twin-screw extruder

CTE twin-screw extruder

sponsored by CTE

Its unique structure—combining a non-intermeshing, counter-rotating twin-screw kneading section with a large-diameter single-screw extrusion section—delivers excellent degassing, kneading, and low-temperature extrusion performance.
This unique structure enables high-quality and stable production in challenging the applications such as high filler compounds and chemical and material recycling.

How CTE’s Twin-Screw Extruders
Transform Your Production Site
Doubling the discharge volume
Defect Rates.
Contact CTE
for more information

CTE’s
Twin-Screw Extruders Revolutionize Production

CTE’s twin-screw extruders fundamentally resolve issues once considered unavoidable with conventional machines—such as feed bottlenecks, uneven compounding performance, and resin thermal degradation.

In the following sections, we’ll explore how these machines deliver revolutionary performance—through their structure, functionality, and operational effectiveness.

01

Double the throughput volume,Dramatically Boost Efficiency

CTE’s twin-screw extruder features a unique design that combines a non-intermeshing, counter-rotating twin-screw kneading section with a large-diameter single-screw extrusion section. This structure maximizes usable space within the cylinder, allowing more material to be conveyed per rotation. Its excellent degassing capabilities also help prevent issues like feed-neck phenomena,enabling higher material input andscrew speeds.

As a result, throughput volume is approximately double *that of conventional intermeshing, co-rotating extruders.*This significantly improves production line efficiency and increases throughput per unit time.

*Based on comparison of throughput between non-intermeshing, counter-rotating and intermeshing, co-rotating twin-screw extruders (screw diameter: 40 mm, data provided by CTE).
02

Advanced degassing capabilityPrevents Molding Defects

The non-intermeshing, counter-rotating twin-screw kneading structure provides significantly better degassing capability compared to conventional systems.Ample clearance between screws allows air and gas generated during kneading to escape smoothly.
Additionally, the reversed resin flow—caused by counter-rotation—helps expel even trapped air bubbles and volatile substances.

As a result,it prevents air bubbles inside pellets—a major cause of molding defects—in applications such as high-filler compoundsand ensures stable quality even when using gas-prone materialslike recycled resins.

03

Low-Temperature Discharge ReducesDefect Rates.

CTE’s tandem twin-screw extruders feature a design that separates the kneading and extrusion stages, enabling the resin to be extruded at low speed and low temperature using a separately driven screw.This independent structure minimizes heat generation during extrusion,effectively reducing issues such as burning and thermal degradation.
Even with oxidation-prone biomass materials or recycled resins with thermal history, the system maintains stable quality while preserving material properties.

As a result, it lowers post-molding defect rates and contributes to reduced production loss and improved yield.

summary
CTE’s Twin-Screw Extruders
Drive Greater Profitability for Plastic Plants

With significantly increased throughput volume, stable molding through air bubble prevention, and suppression of thermal degradation,
CTE’s twin-screw extruders achieve both production efficiency and product quality, helping to resolve key challenges in plastic manufacturing.

By eliminating molding defects and material losses common with conventional machines, CTE’s extruders reduce waste-related costs and improve overall plant profitability.
Visit CTE’s official website to access technical resources and detailed product information for your evaluation.

See More at CTE.com
CTE’s

Twin-Screw Extruders:

Line-up and Use Cases

Highly Concentrated Filler Compounds
and Material Recycling

HTM type tandem kneading extruder

HTM type tandem kneading extruder
*Image taken from: CTE's official website (https://cte-japan.com/en/product/htm-tandem-compounding-twin-screw-extruder/)

Achieves stable dispersion, degassing,
and extrusion even with highly filled materials

In high-density filler compounding and material recycling, challenges like uneven compounding, residual gas, and thermal degradation often hinder productivity.
CTE’s HTM tandem kneading extruder combines a non-intermeshing, counter-rotating twin-screw kneading unit witha single-screw extrusion section for low-temperature, low-speed discharge—fundamentally solving these challenges.

It enhances both product quality and yield by delivering high throughput volume, excellent dispersion, and low-degradation extrusion.

Applications o
f the HTM Tandem Kneading Extruder

  • High-concentration filler compounding
  • Recycled pellet production
  • Advanced chemical and material recycling
  • Re-pelletizing marine plastic waste
  • Re-pelletizing PET bottles and food trays
  • Re-pelletizing plastic parts and cables from used home appliances

The HTM Tandem Solution
to Modern Compounding Challenges

  • Thermal degradation of plastics
  • Molding defects caused by air bubbles
  • Uneven dispersion of high filler content
Screw diameter 38 ～ 120mm
Max. screw speed 450 ～ 800 rpm
Motor capacity 37 ～ 650kw

Implementations o
f CTM Twin-Screw Extruders

  • Recycler: Installed as desalination equipment for chemical recycling
  • Compound manufacturer: Used for producing high-loading calcium carbonate masterbatches
  • Electrical components manufacturer: Introduced to improve quality via enhanced degassing capability
  • Exterior materials manufacturer: Adopted for WPC to suppress thermal degradation
Contact CTE
for more information
Low-Cost, Space-Saving Solution

HTM Twin-Screw Kneading Extruder

HTM Twin-Screw Kneading Extruder
*Image taken from: CTE's official website (https://cte-japan.com/en/product/htm-twin-screw-extruder/)

Pelletizing Wood Flour Without Drying
— Balancing Cost and Quality

CTE’s HTM twin-screw kneading extruder allows direct kneading of unseasoned wood flour with polypropylene (PP), eliminating the need for pre-drying.Thanks to its powerful degassing and compounding, it produces high-quality pelletswithout scorching or color inconsistency.

This also contributes to equipment downsizing and reduced energy consumption, achieving both cost savings and improved efficiency in wood flour compounding.

Implementation Example o
System

  • High-concentration filler compounding
  • Wood flour compounding

Challenges Solved by th
e CTM Twin-Screw Extruder

  • Product discoloration and
    quality loss due to wood flour charring
  • Pre-drying of wood flour
Screw diameter 38 ～ 90mm
Max. screw speed 600 ～ 850 rpm
Motor capacity 22 ～ 350kw

Implementation Example o
f CTM Twin-Screw Extruders

  • Chemical manufacturer: Adopted for commercialization of biodegradable resin and calcium carbonate blending
  • Rubber product manufacturer: Selected for its excellent processing capabilities with elastomer materials
  • Compound manufacturer: Introduced for biomass material (starch) compounding, valued for gas venting and low-temperature extrusion performance
Contact CTE
for more information
For PET sheet line

CTE Sheet Extrusion System

CTE Sheet Extrusion System

PET Hydrolysis Prevention for Consistent Sheet Quality

CTE’s PET sheet production line enables in-extruder drying of PET resin, ensuring stable sheet molding without the need for pre-drying equipment.This not only reduces system costs but also enhancesproductivity.

Applications of the PET Sheet Extrusion
System

Challenges Solved by
e CTM Twin-Screw Extruder

  • Quality degradation
    due to PET hydrolysis
  • Elimination of
    pre-drying processes
  • Enhanced productivity through continuous
    line configuration
Max. extrusion output: 1,000 kg/h
Sheet thickness 0.2mm ～ 2mm
Max. sheet width 2,100mm
Contact CTE
for more information

Why Reconsider T
win-Screw Extruders?

With raw material prices soaring, manufacturers are increasingly turning to highly filled and recycled materials to reduce production costs. However, when using extruders with insufficient compounding performance, these materials can instead cause quality defects and production losses. In fact, many of these issues originate not in the molding process, but during the material kneading stage.

Leverage High-Filler Compounding for Stable Quality and Lower Costs

Highly concentrated masterbatches—containing large amounts of inorganic fillers like calcium carbonate or titanium dioxide—enable stable quality and cost reduction by minimizing the addition rate required in the customer’s production process.
However, their effectiveness depends heavily on the quality of kneading.

Inadequate compounding performance Can Increase Costs

Extruders with poor kneading capability can cause the following problems—leading to losses instead of savings.
  • Inconsistent dimensional accuracy, increasing scrap rates
  • Bubbles and burning due to inadequate degassing after extrusion
  • Incomplete cooling, leading to warping or cracking during molding
  • Uneven coloring, lack of gloss, and other visual defects

To truly reduce costs, the kneading stage prior to molding must be reevaluated.

Many of these defects don’t arise during molding or inspection—they originate in earlier stages such as material preparation and kneading. In many cases, outdated extruders or those not designed for recycled materials fail to meet current raw material requirements—resulting in ongoing waste on the production floor.
That’s why reviewing the compounding performance of twin-screw extruders isa direct and effective cost-reductionstrategy.
CTE's Twin Screw Extruder Revolutionizes Production
View the lineup again
Cost Reduction Strategies

for Plastic
Processed Products

How to reduce the cost of plastic processed products
Reviewing Equipment, Materials, and Processes

As cost reduction becomes a priority on the manufacturing floor, challenges such as material loss, outsourcing expenses, and the handling of recycled materials are becoming more prominent in plastics processing. This section outlineskey cost factors and clearly explains practical cost-cutting methodsthat can be achieved through the introduction of twin-screw extruders.

Learn more on
How to reduce the cost of plastic processed products.
Profitability Improvements

for Plastic Processing
Plants

Plastic processing plants face structural challenges in generating profit due to rising raw material prices and the shift toward high-mix, low-volume production. This section introduces specific strategies to enhance profitability by visualizing the cost structure and implementing targeted on-site improvements.

Reduce Quality Complaints and Waste Costs with Resin Degradation Prevention

Reduce quality complaints and wasted costs

Resin degradation can lead to product defects and quality complaints, severely impacting a company’s credibility and profitability. This section clarifies the degradation mechanisms and associated business risks, and explains essential countermeasures such as temperature control, moisture removal, and stabilizer use—as well as practical improvements using twin-screw extruders.Heating control, moisture removal, stabilizer utilizationand basic measures, as well as practical improvement measures using twin-screw extruders.

Material Handling
to Reduce Plastic Molding Defects

Material handling to reduce molding defects

Most molding defects in plastic manufacturing stem from poor raw material handling. When additives or fillers are poorly dispersed—or when recycled materials are not handled properly—defect rates rise, directly impacting cost and credibility.This section outlines common molding defects and their causes,and provides insights on how to improve quality at the material level for more stable production and better profitability.

Revisiting Raw Material
Costs in Plastic Manufacturing

Costs in Plastic Manufacturing

Soaring raw material prices continue to pressure profitability in plastic manufacturing. What’s needed now is a shift away from purchasing dependency toward anin-house system capable of redesigning and reusing materials.This section reviews structural inefficiencies—such as material waste and poor kneading—and presents methods for optimizing raw material costs.

Twin-Screw Extruders
Fundamentals

Twin-screw extruders deliver excellent compounding performance and high processing capacity, making them ideal for dispersing composites and additives. This section details their basic structure and mechanisms, along with various types and applications. We hope this information proves valuable for your product design and equipment selection decisions.

Comparison Between Twin-Screw and
Single-Screw Extruders

Single-screw and twin-screw extruders are both essential for extrusion molding, but they differ significantly in structure and performance.This sectioncompares their mechanisms, applications, and selection criteria—helping you choose the right equipment based on product complexity, material characteristics, and your production setup.

What Is a Counter-
Rotating Twin-Screw Extruder?

Counter-rotating twin-screw extruders are ideal for low-shear, low-temperature processing, making them suitableheat-sensitive materials such as PVC and natural fiber composites.This section explains their structure, rotational behavior, differences from co-rotating models, and technical advantages. It serves as a useful guide for selecting equipment at sites where molding stability and fiber protection are critical.

PLASTIC PROCESSING

For those considering entering the plastics industry, this section introduces profitable business models and the equipment required. Among them, twin-screw extruders—with their superior compounding performance and flexibility for high-mix, low-volume production—are key to differentiation in areas such as recycled material use and high-performance product manufacturing. Use this information to explore how strong material design capabilities can drive a highly profitable business.

PLASTIC PROCESSING

Bioplastic production

With the growth of the bioplastics market, investment in manufacturing equipment is gaining attention. This section introduces the features of twin-screw extruders capable of handling bio-materials that pose challenges in processing precision and quality stability. It also explores product development and business model opportunities that aim to balance high profitability with environmental value—making this a powerful option for companies pursuing both.

About this Media
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[Twin Screw Hub – Your Comprehensive Guide to Twin-Screw Extruders] is a specialized media platform that provides in-depth, consolidated information about twin-screw extruders. Operated and produced by Zenken Corporation with sponsorship from CTE Corporation, this site is designed for decision-makers in plastic processing plants seeking greater profitability. For factory managers, this guide explains how to leverage high-performance twin-screw extruders to boost productivity, overcome operational challenges, and support business growth.

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