Twin-Screw Extruders for Food Market, Global Outlook and Forecast 2025-2032

MARKET INSIGHTS

Global Twin-Screw Extruders for Food market size was valued at USD 139 million in 2024. The market is projected to grow from USD 142 million in 2025 to USD 161 million by 2032, exhibiting a CAGR of 2.2% during the forecast period.

Twin-screw extruders are advanced food processing machines that utilize two intermeshing screws to mix, cook, and shape raw ingredients into final products. These systems enable precise control over temperature, pressure, and shear forces to produce extruded foods with consistent texture and nutritional content. The technology is widely adopted for manufacturing breakfast cereals, snack foods, pet food, and textured vegetable proteins.

The market growth is driven by increasing demand for processed foods, technological advancements in extrusion systems, and the ability to produce nutritionally enhanced products. Asia-Pacific dominates the market due to rapid urbanization and growing food processing industries in China and India. Key players like Coperion, Clextral, and Bühler are investing in energy-efficient models with Industry 4.0 capabilities to meet evolving production requirements.

MARKET DYNAMICS

MARKET DRIVERS

Rising Demand for Processed Food Products to Accelerate Market Growth

The global twin-screw extruders for food market is witnessing significant growth, primarily driven by the increasing consumption of processed and convenience foods. With urbanization and changing lifestyles, the demand for ready-to-eat snacks, breakfast cereals, and textured vegetable proteins has surged, creating robust opportunities for extrusion technology. Twin-screw extruders offer superior mixing, kneading, and thermal processing capabilities compared to single-screw alternatives, making them ideal for producing complex food textures. The Asia-Pacific region dominates this market segment, accounting for over 40% of global sales, as rapid industrialization and population growth fuel processed food consumption.

Technological Advancements in Extrusion Systems to Enhance Production Efficiency

Continuous innovation in twin-screw extruder design is transforming food manufacturing processes. Modern extruders now feature advanced control systems, improved screw configurations, and energy-efficient operations, enabling processors to achieve higher throughput with better product consistency. The co-rotating segment currently holds more than 65% market share due to its versatility in handling diverse raw materials. Major manufacturers are investing in R&D to develop extruders capable of processing novel ingredients like plant-based proteins, which aligns with the global shift toward sustainable food sources. These technological upgrades are reducing production costs while maintaining superior product quality, making twin-screw extrusion increasingly attractive to food processors.

➤ For instance, leading players like Coperion and Clextral have recently introduced high-capacity extruders with IoT-enabled monitoring systems that optimize energy consumption by up to 20% while improving product uniformity.

Furthermore, government initiatives supporting food processing industries in developing economies are creating favorable conditions for market expansion. Several countries now offer subsidies and tax benefits for adopting advanced food processing technologies, which is expected to drive further adoption of twin-screw extrusion systems.

MARKET RESTRAINTS

High Capital Investment and Maintenance Costs to Limit Market Penetration

While twin-screw extruders offer numerous advantages, their adoption faces significant barriers due to high initial costs and complex maintenance requirements. A typical industrial-scale twin-screw extruder system can cost between $200,000 to over $1 million, depending on capacity and features. Small and medium food processors, especially in developing regions, often find this price prohibitive. Additionally, these systems require specialized personnel for operation and maintenance, with annual upkeep costs averaging 10-15% of the initial investment. This financial burden restricts market growth, particularly among cost-conscious manufacturers operating with thin profit margins.

Other Restraints

Regulatory Compliance Challenges
Stringent food safety regulations governing extrusion processes create compliance burdens for manufacturers. Equipment must meet rigorous hygienic design standards and material specifications, which can delay market entry for new players and increase production costs by 5-8% for existing operators.

Energy Intensive Operations
Twin-screw extruders typically consume 30-50% more energy than conventional processing methods. With rising global energy prices and sustainability concerns, some manufacturers are hesitant to adopt this technology despite its processing advantages.

MARKET OPPORTUNITIES

Expansion into Emerging Markets to Create New Growth Avenues

The growing middle-class population in developing nations presents substantial opportunities for twin-screw extruder manufacturers. Countries like India, Brazil, and Indonesia are experiencing rapid growth in their food processing sectors, with demand for extrusion technology expected to increase by 8-12% annually over the next five years. Local governments are actively encouraging foreign investments in food processing infrastructure through incentives and policy reforms. Manufacturers can capitalize on these trends by offering cost-optimized extruder models tailored to regional requirements and raw material availability.

Alternative Protein Production to Drive Innovation and Demand

The global shift toward plant-based and alternative protein sources is creating new applications for twin-screw extruders. These systems play a critical role in texturizing plant proteins to mimic meat products, with the meat alternatives market projected to exceed $35 billion by 2032. Major food companies are partnering with extrusion equipment manufacturers to develop specialized solutions for novel protein processing. This sector represents a high-growth opportunity as consumer preferences evolve toward sustainable and healthier food options.

MARKET CHALLENGES

Technical Limitations in Processing Novel Ingredients Pose Operational Difficulties

While twin-screw extruders are versatile, they face challenges when processing certain innovative food formulations. High-moisture extrudates, temperature-sensitive ingredients, and unconventional raw material blends often require specialized screw configurations and processing parameters that standard extruders cannot accommodate. This creates production bottlenecks as food developers push the boundaries of product innovation. Approximately 15-20% of new product development projects involving extrusion face technical difficulties related to ingredient compatibility, leading to extended R&D cycles and delayed market launches.

Other Challenges

Skilled Labor Shortage
The operation and maintenance of twin-screw extruders requires specialized technical knowledge that is in short supply globally. Industry surveys indicate that over 35% of food processing plants struggle to find adequately trained extrusion technicians, forcing manufacturers to invest heavily in employee training programs.

Raw Material Variability
Natural variations in ingredient quality and composition can significantly impact extrusion processes and final product characteristics. Processors must constantly adjust parameters to account for these variations, which reduces production efficiency and increases quality control costs.

Segment Analysis:

By Type

Co-Rotating Twin-Screw Extruders Dominate the Market Due to Enhanced Mixing Efficiency

The market is segmented based on type into:

• Co-Rotating

  • Subtypes: Parallel, Tapered, and others

• Counter Rotating

  • Subtypes: Intermeshing, Non-intermeshing, and others

By Application

Human Food Segment Leads Owing to Growing Demand for Processed and Textured Food Products

The market is segmented based on application into:

• Human Food
• Pet Food

By Operation Mode

Continuous Processing Dominates Due to Higher Efficiency in Large-Scale Production

The market is segmented based on operation mode into:

• Continuous Processing
• Batch Processing

By Capacity

Medium Capacity Segment Leads to Balance Between Production Volume and Flexibility

The market is segmented based on capacity into:

• Small (Under 50 kg/hr)
• Medium (50-500 kg/hr)
• Large (Above 500 kg/hr)

COMPETITIVE LANDSCAPE

Key Industry Players

Manufacturers Focus on Technological Innovation to Capture Market Share

The global twin-screw extruders for food market features a mix of established multinational corporations and specialized manufacturers competing on innovation, efficiency, and customization capabilities. Coperion, a subsidiary of Hillenbrand Inc., leads the market with its ZSK food-grade extruders that boast patented screw designs and configurations catering to diverse food processing needs. The company's strong market position stems from its global service network and consistent investment in R&D.

Clextral and Buhler Technologies represent significant European competitors, together accounting for approximately 28% of regional market share according to 2024 estimates. These companies differentiate themselves through specialization in high-capacity systems for snack foods and pet food production, with Clextral's Evolum series gaining particular traction in Asia-Pacific markets.

Mid-sized players like Leistritz and Davis-Standard are gaining ground through targeted solutions for niche applications, including plant-based meat extrusion and functional ingredient processing. The market has seen increased M&A activity, with KraussMaffei group's 2023 acquisition of a majority stake in Coperion signaling broader industry consolidation trends.

Asian manufacturers, particularly JSW and Shibaura Machine, compete aggressively on price-performance ratios while gradually improving their technological capabilities. These regional players now command over 35% of the Asia-Pacific market, the largest single region for twin-screw food extruders.

List of Key Twin-Screw Extruder Manufacturers

• Coperion (Germany)

• Clextral (France)

• Buhler Technologies (Switzerland)

• Leistritz (Germany)

• Milacron (U.S.)

• JSW (Japan)

• Shibaura Machine (Japan)

• KraussMaffei group (Germany)

• Battenfeld-Cincinnati (Austria)

• CPM Extrusion Group (Netherlands)

• Davis-Standard (U.S.)

• NFM (U.S.)

TWIN-SCREW EXTRUDERS FOR FOOD MARKET TRENDS

Increasing Demand for Processed and Convenience Foods to Drive Market Growth

The global twin-screw extruders for food market is witnessing steady growth, primarily driven by rising demand for processed and convenience foods. With urbanization and changing lifestyles, consumers increasingly prefer ready-to-eat and fortified food products. Twin-screw extruders enable manufacturers to produce a variety of textured foods, including snacks, cereals, and pet foods. Their ability to handle high-moisture and high-fat ingredients while maintaining precise temperature control has made them indispensable in large-scale food processing. Furthermore, the Asia-Pacific region leads the market due to rapid industrialization and population growth, generating over 38% of global demand for extruded food products.

Other Trends

Adoption of Co-Rotating Twin-Screw Extruders

Co-rotating twin-screw extruders dominate the market, holding nearly 65% share in 2024 due to their superior mixing efficiency and versatility. These extruders provide better control over shear force and residence time, making them ideal for producing textured vegetable proteins (TVP) and high-fiber snacks. With plant-based food alternatives gaining traction, manufacturers are investing in advanced co-rotating systems to improve product consistency and nutritional profiles. Their adaptability in handling multiple ingredient combinations further strengthens their market position.

Technological Advancements in Extrusion Systems

Recent advancements in twin-screw extrusion technology have led to more energy-efficient and precise systems capable of processing diverse raw materials. Modern extruders now feature intelligent control systems with real-time monitoring, reducing waste and improving throughput. The integration of automation and Industry 4.0 technologies has further optimized production processes, enabling manufacturers to scale operations while maintaining high-quality standards. Additionally, innovations in segmented barrel designs allow for greater flexibility in handling both viscous and dry formulations, making them essential for future-ready food production.

Regional Analysis: Twin-Screw Extruders for Food Market

North America
The North American twin-screw extruders market is characterized by high adoption of advanced food processing technologies and strong demand for convenience foods. The U.S. dominates the region, driven by widespread use in snack production and pet food manufacturing. However, adoption of counter-rotating extruders remains limited due to higher energy requirements. Stringent food safety regulations, including FDA compliance standards, are pushing manufacturers toward precision-engineered extrusion systems. A growing interest in plant-based proteins - expected to reach $7 billion in sales by 2025 - is creating new opportunities for extruder manufacturers to develop specialized configurations for meat alternatives.

Europe
Europe's market is defined by innovation in functional foods and sustainability-focused processing. Germany and France lead in adopting co-rotating extruders for their energy efficiency in producing breakfast cereals and textured vegetable proteins. The region's strict EU food contact material regulations (EC 1935/2004) necessitate extruders with advanced material compatibility. Equipment automation is becoming crucial to meet labor cost challenges, with over 60% of new installations incorporating Industry 4.0 features. The rising demand for clean-label products and organic ingredients presents both opportunities and technical challenges for extrusion system providers needing to maintain product integrity at industrial scales.

Asia-Pacific
As the largest and fastest-growing market, Asia-Pacific exhibits diverse demand patterns. China's massive snack food industry - valued at over $70 billion - heavily utilizes mid-range twin-screw systems, while Japan focuses on high-precision configurations for specialized nutritional products. Price sensitivity in developing markets like India and Indonesia encourages localization of manufacturing, with companies like USEON and XINDA gaining market share. However, inconsistent power supply infrastructure in some areas limits adoption of high-capacity systems. The rapid expansion of pet food production facilities across Southeast Asia represents a significant growth vector for extruder suppliers through 2030.

South America
The South American market shows moderate but steady growth, led by Brazil's well-established food processing sector. Most demand comes from staple food fortification programs and extrusion-cooked feed production. Economic volatility affects capital investment cycles, causing preference for retrofitting existing systems rather than new purchases. The Andean region shows emerging potential for small-scale extruders serving quinoa and other ancient grain processing. Limited local manufacturing capability results in dependence on imported equipment, primarily from European and Chinese suppliers, creating logistics challenges that impact total ownership costs.

Middle East & Africa
This developing market is seeing increased activity, particularly in GCC countries investing in food security initiatives. The UAE and Saudi Arabia are establishing extrusion hubs for dates processing and halal-certified products. In Africa, South Africa leads in commercial adoption while other nations mainly utilize small-scale systems for basic food production. Infrastructure limitations and irregular maintenance support networks constrain market expansion, though development financing from multilateral agencies is beginning to improve equipment accessibility. The region's focus on reducing post-harvest losses through extrusion technology presents long-term opportunities, particularly in cereal and tuber processing applications.

Report Scope

This market research report offers a holistic overview of global and regional markets for the forecast period 2025–2032. It presents accurate and actionable insights based on a blend of primary and secondary research.

Key Coverage Areas:

• ✅ Market Overview

  • Global and regional market size (historical & forecast)

  • Growth trends and value/volume projections

• ✅ Segmentation Analysis

  • By product type or category

  • By application or usage area

  • By end-user industry

  • By distribution channel (if applicable)

• ✅ Regional Insights

  • North America, Europe, Asia-Pacific, Latin America, Middle East & Africa

  • Country-level data for key markets

• ✅ Competitive Landscape

  • Company profiles and market share analysis

  • Key strategies: M&A, partnerships, expansions

  • Product portfolio and pricing strategies

• ✅ Technology & Innovation

  • Emerging technologies and R&D trends

  • Automation, digitalization, sustainability initiatives

  • Impact of AI, IoT, or other disruptors (where applicable)

• ✅ Market Dynamics

  • Key drivers supporting market growth

  • Restraints and potential risk factors

  • Supply chain trends and challenges

• ✅ Opportunities & Recommendations

  • High-growth segments

  • Investment hotspots

  • Strategic suggestions for stakeholders

• ✅ Stakeholder Insights

  • Target audience includes manufacturers, suppliers, distributors, investors, regulators, and policymakers

FREQUENTLY ASKED QUESTIONS:

What is the current market size of Global Twin-Screw Extruders for Food Market?

-> The Global Twin-Screw Extruders for Food market was valued at USD 139 million in 2024 and is projected to reach USD 161 million by 2032, growing at a CAGR of 2.2% during the forecast period.

Which key companies operate in Global Twin-Screw Extruders for Food Market?

-> Key players include Coperion, Milacron, JSW, Shibaura Machine, Leistritz, KraussMaffei group, Battenfeld-Cincinnati, Clextral, CPM Extrusion Group, Davis-Standard, among others.

What are the key growth drivers?

-> Key growth drivers include rising demand for processed food, increasing pet food consumption, and technological advancements in extrusion technology.

Which region dominates the market?

-> Asia-Pacific is the largest market for Twin-Screw Extruders for Food, driven by high population density and growing food processing industry.

What are the emerging trends?

-> Emerging trends include energy-efficient extruders, smart automation solutions, and sustainable food production technologies.