Co-Rotating Twin-Screw Technology for Green-Tech: Recycling, Bioplastics and Direct Extrusion
Green-Tech with Co-Rotating Twin-Screw Technology: Recycling, Bioplastics & Direct Extrusion
Green-Tech Processing with Co-Rotating Twin-Screw Extrusion
ICMA’s co-rotating twin-screw extrusion technology is a core enabler for green-tech applications, supporting sustainable material development through recycling, bioplastics, natural fibers and direct extrusion processes.
Rather than focusing on a single approach, ICMA systems are designed to handle a wide range of sustainable materials and processes, enabling manufacturers to transition toward more environmentally responsible solutions without compromising industrial performance.
Advanced recycling and up-cycling of polymers
In recycling applications, ICMA co-rotating extruders enable advanced up-cycling, particularly when:
- processing difficult or heterogeneous recycled materials
- upgrading recyclates to replace virgin polymers in technical applications
- achieving high and stable production capacity, often leading processors to move from single-screw to co-rotating twin-screw extrusion
Through intensive and controlled mixing, devolatilization and melt purification, recycled polymers can reach consistent quality levels suitable for demanding markets.
Processing of bioplastics and bio-based materials
Co-rotating twin-screw technology is equally suited for the processing of bioplastics, including starch-based formulations, PHAs and other bio-derived polymers.
These materials often require:
- precise thermal control
- gentle yet effective mixing
- flexible screw configurations
ICMA extruders provide the necessary process stability to preserve material integrity while ensuring homogeneous compounds and repeatable production conditions.
Natural fibers and sustainable composites
ICMA systems are widely used for the compounding of natural fibers and cellulose-based materials, either as stand-alone compounds or in combination with polymers and biopolymers.
The co-rotating twin-screw design allows:
- controlled fiber dispersion
- addition of fillers and reinforcements directly into the melt
- development of sustainable composites with tailored mechanical properties
This opens new market opportunities in technical and semi-structural applications where sustainability and performance must coexist.
Direct extrusion as a sustainable production strategy
Direct extrusion (in-line compounding) plays a key role in green-tech manufacturing.
By combining material formulation and final extrusion in a single continuous process, ICMA co-rotating extruders enable:
- elimination of intermediate pelletizing
- reduced energy consumption
- minimized thermal history of the material
- leaner and more efficient production layouts
Direct extrusion is applied to recycled polymers, bioplastics and natural fiber-filled compounds, supporting both environmental and economic sustainability.
Energy efficiency, odor control and process flexibility
Across all green-tech applications, ICMA co-rotating extrusion systems deliver:
- high energy efficiency compared to conventional technologies
- advanced, including patented, odor removal and degassing solutions
- flexible machine layouts tailored to specific material and process requirements
Each system is engineered to address the full spectrum of green-tech challenges, from material development to industrial production.
From sustainable material development to industrial scale-up
ICMA green-tech solutions are designed to ensure reliable scale-up, with processes that can be developed and validated on Lab & Pilot extrusion systems and transferred seamlessly to full-scale production lines.
FAQ – Green-Tech & Co-Rotating Twin-Screw Technology
Why are co-rotating twin-screw extruders suitable for green-tech applications?
Co-rotating twin-screw extruders provide controlled and intensive mixing, high process flexibility and stable operation, which are essential when processing recycled materials, bioplastics and natural fiber compounds.
How does co-rotating twin-screw extrusion support polymer recycling and up-cycling?
Through efficient mixing, devolatilization and melt purification, recycled polymers can be upgraded to achieve consistent quality levels, making them suitable for technical and industrial applications.
Is it possible to compound natural fibers without damaging them?
Yes. The screw geometry and process control of ICMA extruders allow effective fiber dispersion while minimizing thermal and mechanical stress, preserving fiber integrity.
What are the benefits of direct extrusion (in-line compounding) in green-tech processes?
Direct extrusion combines compounding and final shaping in a single step, enabling energy savings, reduced thermal history of the material and simpler production layouts.
Which materials can be processed using direct extrusion technology?
Direct extrusion can be applied to recycled polymers, bioplastics and natural fiber-filled compounds, supporting both environmental and economic sustainability.
How does ICMA address odor removal in recycling applications?
ICMA integrates advanced, including patented, degassing and deodorization solutions to efficiently remove volatile contaminants and improve melt quality.
Can green-tech processes be validated before industrial production?
Yes. ICMA provides Lab & Pilot extrusion systems that allow customers to develop, test and validate processes before scaling up to full industrial production.
Why choose ICMA for green-tech extrusion systems?
Because ICMA combines exclusive expertise in co-rotating twin-screw technology, in-house engineering, process know-how and a complete lab-to-production approach.
Depending on the type of tasks required different layout can be designed. More details by clicking the following button.
HDPE - PP:
ORIGIN: Post-consumer liquid container bottles (milk, juice) jars (detergent) food trays, industrial bins, car fuel tanks
PRE- PROCES: Generally, come from a separation and washing system
PROCESS TASK:
- Mix the polymers with different viscosity
- Keep the polymer mechanical characteristics without degradation
- Perfect degassing for good post-processing (injection molding
- Fine filtration
REMARKS: Is a high bulk density material, easier to feed
TURN KEY LINE:
- Flakes and additive handling
- Loss in weight gravimetric system
- High torque co-rotating extruder
- Continuous screen changer ( no firm links with suppliers)
- Water ring or underwater pelletizing system
- Final material handling and packing (big bags)
Proven screw geometry perfect melting/dispersion of very low MFI fraction
- Lower residence time under controlled shear & thermal conditions
- Multiple highly efficient degassing ports
- Double filtration system
ICMA's line FOR ALL PROCESSING TASK:
- Line including MCM 140 HT capacity up to 4,5 t/h
- Line including MCM 110 HT capacity up to 2,5 t/h
- Line including MCM 90 HT capacity up to 1 t/h
In Film recycling ICMA has addressed some major issues one of which is the feeding of the extremely light film materials. Such compelling task is achieved by a patented system that allows to continuously feed the extruders by also granting a high production yield.
Another advantage of our "one-step" approach is also to avoid expensive and "energy hungry" boiler units upstream frequently proposed by other suppliers.
Contact us
In very specific cases cascade design is advisable, for instance, when a very tight filtering process is required before the compounding stage can be started.
Here we recommend to design the line using 2 co-rotating extruders, the first to execute the efficient degassing and filtering tasks and he second for compounding . An upstream single extruder may also be considered although the overall performance level will be affected.
Contact us
ICMA has developed a very advanced process technology to minimize contaminants up to 95% in the plastic melt during a recycling process.
Typical feed-stock waste coming from detergent bottles and fuel tanks carries unpleasant odours difficult to extract and eliminate.
This effective technology solution from ICMA is based on a combination of venting devices and stripping agent (e.g. water) that are injected
along the barrel of the co-rotating extruder through well defined injection points.
The platform is validated on industrial lines that produces in modern factories based in Europe.
Come to our INNOVATION HUB to tests your materials !
Several other materials are nowadays finding a new life with our co-rotating extruders. The more common are plastic parts of electrical devices (RAEE) or PET, ABS etc etc .
Just enquire ICMA and come to our Innovation Hub to test your scrap!
Contact us
With several lines turn-key or just extruders designed to process bioplastics (such as starch base , compounds made of PLA, PHA, PBSI, PBAT, ...) ICMA can be the partner of choice to supply a reliable system. Starting in our Innovation Hub with trials to check processability of your formulation.
Contact us
Our knowledge in mixing natural fibres and a polyolefin roots back to the early 70’s when ICMA successfully pioneered, first in the World, the process technology for producing a thermoformable sheet for automotive interior trims made of virgin or recycled polypropylene and wood flour.
Today are available compounding and extrusion solutions.
Contact us
The direct extrusion of sheets made of recycled resins allows the value increasing of a “poor” product.
The use of a co-rotating extruder allows the feeding of recycled scraps with a low selecting level, therefore cheaper.
From industrial wastes or selected post consumer scraps it is possible to obtain sheets having good mechanical properties that can be engineered with the addition of mineral fillers or reinforced and possibly further improved with the application of co-extruded aesthetic film.
Contact us