In the context of the global circular economy's rapid development by 2026, plastic granulation technology has become crucial for determining the profitability of recycled resource companies. Faced with a wide array of single-screw and twin-screw extruders on the market, recyclers often face a dilemma: should they prioritize ultimate cost-effectiveness or invest in a high-tech production line? This article will help you make an informed decision by examining three dimensions: technical principles, application scenarios, and ROI (Return on Investment).
Single Screw Extruder:
Principle: Relies on friction and shear force for physical conveying.
Advantages: Simple structure, low energy consumption, and extremely low maintenance costs.
Limitations: Weak mixing and dispersion capabilities, poor compatibility with complex formulations.
Twin Screw Extruder:
Principle: Intermeshing screws achieve forced conveying and "C"-shaped high-frequency shearing.
Advantages: Excellent homogenization effect, strong degassing performance, and supports online modification (e.g., adding glass fiber, flame retardants).
Limitations: High initial investment, higher operating skill requirements.
II. 2026 Market Application Guide: Scenario-Driven Selection
| Demand Dimension | Recommended Choice: Single Screw | Recommended Choice: Twin Screw |
| Material Type | Clean industrial scraps, single-component PET/HDPE | Mixed waste plastics, films containing impurities, high-moisture materials |
| Product Positioning | Basic recycled materials (garbage bags, building materials) | Engineering plastics, modified plastics, substitutes for virgin materials |
| Core Requirements | Lower operating costs, quick return on investment | Increased added value, product consistency, multi-functionality |
III. Procurement Decision Model: Three Key Dimensions
Raw Material Complexity: Does your raw material contain residual glue, printing ink, or multiple components? If so, the self-cleaning and degassing functions of a twin-screw extruder are essential.
Downstream Customer Requirements: Are your customers manufacturing simple pallets or automotive parts? High-value-added orders require the stable performance of a twin-screw extruder. Long-term maintenance costs: Considering the projected increase in labor costs by 2026, the ease of maintenance of single-screw extruders is more advantageous for small-scale factories, while large automated factories prefer the intelligent monitoring systems of twin-screw extruders.
IV. Conclusion: The Balance Point Between Efficiency and Profit
There is no absolutely perfect equipment, only the solution that best fits the business model.
Single-screw extruders are the "cornerstone" for stable profits, suitable for standardized, large-scale production.
Twin-screw extruders are the "engine" for industrial upgrading, suitable for companies pursuing high-value-added products and diversified operations.
V. Frequently Asked Questions (FAQ)
Q1: Which is more energy-efficient, single-screw or twin-screw?
A: Under the same production capacity, single-screw extruders are usually more energy-efficient. This is because the single-screw structure is simple, the frictional heat generation efficiency is high, and there is no complex transmission system. However, if processing high-humidity or complex materials requiring deep degassing, twin-screw extruders, with their efficient degassing and homogenization capabilities, can reduce the scrap rate of secondary processing. From the perspective of comprehensive energy consumption per unit of qualified product, twin-screw extruders have an advantage in large-scale modification production.
Q2: If my raw materials contain metal impurities or sand, which machine is more durable?
A: Single-screw extruders perform better in terms of wear resistance. Due to the larger gap between the barrel and the screw and the robust structure of the single-screw machine, it is less sensitive to hard impurities. Due to the tight meshing of twin-screw extruders, hard foreign objects can easily cause screw jamming or tooth breakage. Recommendation: Regardless of which type you choose, a high-strength magnetic separator and melt filter must be installed at the front end.
Q3: Can twin-screw extruders completely replace single-screw extruders?
A: No. They are complementary rather than substitutive. In the large-scale recycling of pure materials (such as PET bottle flakes, PE film industrial waste), single-screw extruders dominate due to their extremely high cost-effectiveness and stability. Twin-screw extruders mainly address the value enhancement (upcycling) process from waste materials to high-performance materials.
Q4: Why are twin-screw granulators usually 2-3 times more expensive than single-screw granulators?
A: The cost difference mainly stems from:
Gearbox structure: Twin-screw extruders require high-torque, high-precision distribution gearboxes, which have extremely complex manufacturing processes.
Screw design: Twin screws typically use a modular (segmented) design, requiring higher-grade materials (such as high-performance alloy steel).
Control system: Twin-screw extruders are usually equipped with more sophisticated automated control systems to monitor complex process parameters.
Q5: What will be the mainstream "second-stage recycling system" in 2026?
A: The most advanced solution currently is the "single-screw plus twin-screw" two-stage extrusion granulation line. That is: the first stage uses a single-screw extruder with a large length-to-diameter ratio for pre-melting and coarse filtration, and the second stage uses a co-rotating twin-screw extruder for deep degassing, additive addition, and fine modification. This combination integrates the strong adaptability of single-screw extruders and the high dispersion capabilities of twin-screw extruders, making it the preferred solution for producing high-quality recycled materials.