Gitnux/Report 2026

Extrusion Industry Statistics

From 4.6% aluminum extrusion market growth projected through 2030 to a 5.1% rebound for plastic extrusion through 2032, this page pairs hard market sizing with the operational levers that actually move margins and emissions. Expect striking benchmarks like 2.3% of global CO2e tied to manufacturing and construction, 25% of aluminum extrusion cost driven by energy, and 0.3 tCO2e per tonne when renewable electricity powers production, alongside adoption stats on sensors, MES, and connected maintenance that explain why some plants cut scrap and downtime faster.
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November 11, 2026Updated
Extrusion Industry Statistics
Megan GallagherWritten by Megan Gallagher·Edited by Leah Kessler·Fact-checked by Rajesh Patel
Published ·Updated
How this report is researched
01Editorial Scope

Before any source is gathered, an editor locks the question, what qualifies, and how the piece will be judged.

02Source Research

Search agents collect the source set and pull each data point out with its provenance attached.

Read our full methodology →

Search agents attach provenance to every extracted figure.

Next review: within 31 days

01 Industry overview

The extrusion industry at a glance

The global plastics extrusion market was valued at $238.99 billion in 2025 and is forecast to reach $319.21 billion by 2030, while aluminium extrusion remains regionally concentrated and increasingly tied to recycling and low-carbon demand.

$238.99B[68]
Plastics extrusion market, 2025
5.9%[68]
Plastics extrusion CAGR, 2026–2030
48.1%[24]
Asia-Pacific extruded plastics share, 2023
15,168[60]
U.S. aluminium extrusion workers, 2022
Market size
The global plastics extrusion market was valued at $238.99 billion in 2025 and $254.04 billion in 2026. The global extruded plastics market, a related finished-products measure, was estimated at $170.74 billion in 2023.[68][24]
Forecast & CAGR
The plastics extrusion market is projected to reach $319.21 billion by 2030, representing a 5.9% CAGR from 2026 onward. The extruded plastics market is forecast to reach $221.18 billion by 2030 at a 3.9% CAGR from 2024 to 2030.[68][24]
Market share & regions
Asia-Pacific held 48.1% of the global extruded plastics market in 2023 and was identified as the largest regional market in 2025 for plastics extrusion. Hydro reported 2025 aluminium extrusion market shares of 14% in Europe and 18% in North America.[24][23]
Segmentation
Extrusion demand is segmented by material, including polyethylene, PVC, polystyrene and polycarbonate, and by end use, including construction, packaging, automotive, electrical and electronics, healthcare, aerospace and transportation. In plastic extrusion machinery, construction generated $2.03 billion in revenue in 2022.[24]
Key players & concentration
The market includes large diversified materials and packaging companies such as Saint-Gobain, Amcor, REHAU, Aliaxis, Georg Fischer, China Lesso, JM Eagle and Advanced Drainage Systems. In aluminium extrusion, Hydro reported 1.4 million tonnes of annual capacity, 1.0 million tonnes of sales and 69 production sites in 20 countries in 2025.[68][23]
Pricing
Pricing is exposed to resin and aluminium input costs, trade measures and product mix. In the U.S. aluminium extrusion investigation covering 2021–2023, domestic producers raised sales prices for four of five examined products while capacity utilization fell from 83.5% in 2021 to 70.1% in 2023.[60]
Trends, drivers & challenges
Growth is supported by construction, packaging, automotive, electrical and medical applications, while recycling and lightweighting are strengthening demand for advanced extrusion. The main challenges are weaker industrial output, supply-chain disruption, environmental restrictions on plastics and excess capacity; Hydro reported a proposal to close five European extrusion plants during 2026.[24][23]
Consumer behavior & competition
End-user and consumer demand is shifting toward recyclable packaging, recycled content and clearer waste-sorting information. EU packaging rules require all packaging to be recyclable by 2030 and establish minimum recycled-content requirements for plastic packaging from 2030, increasing competition around material efficiency, compliance and circularity.[69][70]
M&A
Consolidation continues in extrusion equipment and specialist converting. In July 2026, MAAG Group announced a definitive agreement to acquire Cloeren, a producer of extrusion slot dies and feedblocks for polymer and plastics applications; in March 2026, Verzatec Group acquired Ultra Tech Extrusions, expanding into custom furniture profiles.[71][72]
Regulation
The EU Packaging and Packaging Waste Regulation entered into force on February 11, 2025 and applies from August 12, 2026. It requires, from 2030, recycled content in plastic packaging, including 30% for PET contact-sensitive packaging, 30% for single-use plastic beverage bottles and 35% for other plastic packaging; U.S. plastic extrusion operations are also covered by EPA plastics molding and forming effluent guidelines in relevant applications.[70][73]
Latest news
The most recent identified major extrusion transaction was MAAG Group’s July 28, 2026 announcement that it had agreed to acquire Cloeren. The deal is intended to expand MAAG’s integrated plastics-processing and extrusion technology offering.[71]

02 Ranking

Top 10 Companies in the Extrusion Industry

The leading companies in the extrusion industry, ranked on market impact, performance, momentum, innovation and brand popularity.

Updated November 11, 2026 · Next review December 11, 2026

Verdict

Hindalco Industries leads Gitnux's 2026 extrusion ranking with an Overall score of 9.8, with 90 kilotonnes of aluminum extrusion production in FY2025-26. REHAU Group is the highest-ranked polymer profile extruder at 9.1, with extrusion used to produce polymer profiles, tubing and seals for construction and industrial markets.

Ranked by Overall score · How we score ↓

Editor's top 3 picks

Where to start, by need.

  1. #1 Overall · Leader in aluminum extrusion

    Hindalco Industries

    IN

    Ranked #1 · 9.8 · Aluminum extrusion

    Why we picked it: Integrated aluminum extrusion and downstream products, backed by 90 kilotonnes produced in FY2025-26.

    See in ranking ↓Visit hindalco.com ↗

  2. Leader in polymer profiles extrusion

    REHAU Group

    DE

    Ranked #2 · 9.1 · Polymer profiles extrusion

    Why we picked it: Polymer profiles, tubing and seals use extrusion across construction and industrial end markets.

    See in ranking ↓Visit rehau.com ↗

  3. Leader in aerospace and transportation extrusion

    Arconic

    US

    Ranked #3 · 9.0 · Aerospace and transportation extrusion

    Why we picked it: A dedicated Extrusions business serves aerospace and transportation, focused on specialized extrusion supply.

    See in ranking ↓Visit arconic.com ↗

Pick 1 is the #1 company overall. Picks 2 and 3 are the highest-ranked companies in the top 5 that add a new segment.

Full ranking

Sort by
Top 10 companies in the extrusion industry, 2026 – Gitnux ranking
#CompanyOverall ↓Company snapshot
1

Hindalco Industries

Aluminum extrusion · IN

9.8
2

REHAU Group

Polymer profiles extrusion · DE

9.1
3

Arconic

Aerospace and transportation extrusion · US

9.0
4

Kaiser Aluminum

Aluminum extrusion · US

9.0
5

JM Eagle

Plastic pipe extrusion · US

9.0
6

Hydro

Global aluminum extrusion and recycling · NO

8.9
7

Constellium

Advanced aluminum automotive and industrial extrusions · FR

8.9
8

Technoform

Precision thermoplastic profile extrusion · DE

8.8
9

Gulf Extrusions

Architectural and industrial aluminum extrusion · AE

7.8
10

Westlake

PVC pipe, profiles and extrusion compounds · US

7.6

How we score

  • Impact (30%): scale and weight in the market (revenue, market share, employees, market position).
  • Performance (20%): recent revenue growth and operating margin; an analyst assessment where a company does not publish them.
  • Momentum (20%): growth trajectory and future potential.
  • Innovation (15%): R&D intensity and how technologically advanced the company is.

Popularity (brand search demand, 15%) counts toward Overall but is not published as a column. Overall leaves out what is not known.

Scale Scores are shown on a 7–10 scale with one decimal; bars start at 7.0.

Cadence Recalculated when new figures are published; next review December 11, 2026.

Independence. Rankings are editorially independent. Scores, ranks, picks and the verdict follow the method above; no company can pay to change them.

Cite this ranking

APA

Megan Gallagher. (2026, February 13). Top 10 companies in the extrusion industry. In Extrusion Industry Statistics. Gitnux. https://gitnux.org/extrusion-industry-statistics/#top-companies

report visual · Comparison

Aluminium extrusion imports

Germany leads with $2.8B.

Germany$2.8B
United States$1.5B
France$1.5B
Netherlands$780.0M
Poland$760.0M
source-verifiedfliphtml5.com

04 Statistics

Technology & Innovation

U.S. operator time that is projected to be technically automatable by AI reaches 7% by end of 2028. Industry surveys also track AI rollout in rubber-and-plastics process manufacturing at 6% in 2025.

AI in the extrusion industry

  • 7% of the working time of U.S. metal-and-plastic extruding and drawing machine operators is projected to be technically automatable by AI by the end of 2028.[1]
  • 6% of respondents in the rubber-and-plastics process-manufacturing segment reported rolling out AI in the 2025 survey, a category that includes plastics extrusion operations.[2]
  • 6% of the working time of U.S. metal-and-plastic extruding and drawing machine operators could theoretically be performed by current AI models, according to a task-level assessment in 2026.[1]

Automation in the extrusion industry

  • 205 U.S. job postings carried the title “extrusion technician” in the recent occupation-level job-posting data.[3]
  • 330 plastics-industry respondents participated in Plastics Information Europe’s 2023 survey examining the impact of AI and automation on European plastics processing, including extrusion.[4]
  • 60,840 people were employed in the United States in the metal-and-plastic extruding and drawing machine setter, operator and tender occupation in the latest occupation profile.[1]

Digital Transformation in the industrial manufacturing sector (sector benchmark)

  • 24% of companies across the European Industrial Ecosystem had a concrete digital-transformation strategy in 2024.[5]
  • 76% of industrial-manufacturing firms across 26 countries reported that their workforce had an appetite to embrace cutting-edge technology in 2024.[6]
  • 32% of U.S. industrial-products respondents said their operations-technology investments had delivered expected results in 2024.[7]
  • 34% of industrial-manufacturing organizations across 26 countries had achieved return on investment from multiple AI use cases in 2024.[6]

Technology Adoption in the industrial manufacturing sector (sector benchmark)

  • 35% of industrial-manufacturing organizations were proactive in advancing data-and-analytics strategies in 2024.[8]
  • 30% of industrial-manufacturing organizations were proactive in advancing edge-computing strategies in 2024.[8]
  • 31% of industrial-manufacturing organizations were proactive in advancing modern-delivery technologies, including low-code and no-code, in 2024.[8]
  • 37% of industrial-manufacturing organizations were proactive in advancing AI and automation strategies in 2024.[8]

Cloud Computing in the industrial manufacturing sector (sector benchmark)

  • 87% of Finnish manufacturing enterprises used cloud computing in 2023.[9]
  • 39% of industrial-manufacturing organizations were proactive in advancing XaaS technologies, including public and multicloud, in 2024.[8]
  • 87% of Australian manufacturing enterprises used cloud computing in 2022.[9]
  • 54% of EU manufacturing enterprises used paid cloud-computing services in 2025, up from approximately 45% in 2023.[10]

Big Data in the industrial manufacturing sector (sector benchmark)

  • 70% of manufacturers still collected data manually in 2024, according to a Manufacturing Leadership Council survey reported by the National Association of Manufacturers.[11]
  • 33% of manufacturers surveyed were performing prescriptive analytics in 2024, according to ABI Research’s survey of 461 manufacturing decision makers.[12]
  • 67% of manufacturers surveyed in the United States, Germany and Malaysia could collect and analyze data in near real time in 2024.[12]
  • 28% of manufacturing survey respondents were implementing big-data processing in 2024, up 7 percentage points from 2023, according to an Auburn University study of 97 participants.[13]
  • 16.2% of businesses in the European Industrial Ecosystem used big-data technologies in 2024.[5]
  • 28% of manufacturing survey respondents were implementing big-data processing in 2024.[13]

Blockchain in the extrusion industry

  • 1 blockchain collaboration between Covestro, Circularise and Domo Chemicals was reported for tracing plastic-waste origin and composition through fragmented plastics supply chains.[14]
  • 1 blockchain-enabled plastics-traceability pilot, reciChain Canada, was designed to track recycled plastics through the value chain, with the digital tracing technology surviving extrusion.[15]

IoT in the industrial manufacturing sector (sector benchmark)

  • 35% of manufacturing companies in a Productivity Institute sample had adopted Internet of Things technology, with geography not specified by the source.[16]
  • 81% of manufacturing leaders surveyed identified data and analytics for process improvement as an important technology use case, while IoT for predictive maintenance ranked among the leading use cases in 2024.[17]
  • 11.1% of businesses in the European Industrial Ecosystem used Internet of Things technologies in 2023.[5]
  • 27.6% of businesses in the European Industrial Ecosystem used Internet of Things technologies in 2024.[5]

05 Statistics

Data & Analytics

Extrusion analytics performance is tracked via scrap, startup-time, and energy metrics (e.g., up to 22% scrap reduction and 35% startup-time reduction). Data quality remains a constraint, with 44% of AI projects failing due to poor data quality in 2025.

Business intelligence in the extrusion industry

  • €1.2 million per year was the maximum improvement potential reported across five extrusion lines by HMR-EPI.[18]
  • 6–12 months was the typical return-on-investment period reported for HMR-EPI’s extrusion process-intelligence application.[18]
  • 22% was the maximum scrap reduction reported by HMR-EPI for extrusion operations.[18]
  • 35% was the maximum startup-time reduction reported by HMR-EPI for extrusion operations.[18]
  • 12% was the maximum energy-consumption reduction reported by HMR-EPI for extrusion operations.[18]
  • 15% was the maximum productivity improvement reported by HMR-EPI for extrusion operations.[18]

Data analytics in the extrusion industry

  • 22% was the maximum scrap reduction reported by HMR-EPI from extrusion-process analytics.[18]
  • 5 of 8 presses supplied press-IoT data to SYHARVEST’s manufacturing-execution system from January 2023 onward.[19]
  • 15% was the maximum productivity improvement reported by HMR-EPI from extrusion-process analytics.[18]
  • Three of SYHARVEST’s eight extrusion presses were not connected to the manufacturing-execution system in 2026.[19]
  • 35% was the maximum startup-time reduction reported by HMR-EPI from extrusion-process analytics.[18]
  • About one minute was required to retrieve digital production traceability data at SYHARVEST in 2026.[19]

Data Quality in the industrial manufacturing sector (sector benchmark)

  • 54% of manufacturers surveyed had duplicate data in several systems in 2025.[20]
  • 61% of manufacturing leaders agreed that poor data quality limited adoption and optimization of emerging technologies in 2025.[21]
  • 41% of manufacturers surveyed distrusted the data used for supply-chain operations in 2025.[20]
  • 30% of manufacturers identified poor data quality as a technical barrier to improving processes in 2025.[21]
  • 44% of manufacturers surveyed reported that AI projects had failed because of poor data quality in 2025.[20]
  • 51% of manufacturers surveyed said their data was siloed across disparate tools and systems in 2025.[20]

Data Governance in the industrial manufacturing sector (sector benchmark)

  • 15% of manufacturers surveyed said their data strategy was entirely aligned with their overall business strategy in 2024.[22]
  • 22% of manufacturers surveyed included data collection, management or analysis in executive incentives, KPIs or business imperatives in 2024.[22]
  • 61% of manufacturers surveyed had a corporate-wide governance plan, strategy or formal data-management guidelines in 2024.[22]
  • 58% of manufacturers surveyed assigned primary data-governance responsibility to a C-suite or senior leader in 2024.[22]

KPIs in the extrusion industry

  • 5–7 days was SYHARVEST’s mill-finish extrusion lead-time KPI in 2026.[19]
  • 15–18 days was SYHARVEST’s machined-extrusion lead-time KPI in 2026.[19]

06 Statistics

Strategy & Growth

Recycling capacity and extrusion-line investments drive growth targets, including Hydro’s 50,000 tonnes recycling-capacity increase from Cressona in 2024. Hydro also targeted a 27% reduction in CO2 emissions from extrusion billets by 2030 versus 2018.

Growth in the extrusion industry

  • 50,000 tonnes was the recycling-capacity increase from Hydro’s Cressona, Pennsylvania, expansion in 2024.[23]
  • 3.9% was the projected compound annual growth rate of the global extruded-plastics market from 2024 to 2030.[24]
  • 30% was the planned capacity increase from Hydro’s fourth extrusion line at Nenzing, Austria.[23]
  • EUR 45 million was Hydro’s investment to increase sustainable extrusion capacity at Nenzing, Austria.[23]
  • NOK 10–12 billion was Hydro Extrusions’ 2030 normalized-market EBITDA target after improvements.[23]
  • EUR 14.8 million was Hydro’s investment to upgrade recycling capacity at its Atessa, Italy, extrusion plant.[23]

Differentiation in the extrusion industry

  • 50 years of aluminium extrusion expertise was cited by Hydro Extrusions as part of its customer value proposition in 2024.[23]
  • 27% was Hydro Extrusions’ targeted reduction in carbon dioxide emissions from extrusion billets by 2030 versus 2018.[23]
  • Over 400 employees worked at Hydro’s Nenzing extrusion plant, which served more than 1,000 customers in German-speaking markets.[23]
  • Three partnership levels—Hydro Partner, Hydro Plus Partner and Hydro Innovative Partner—were offered to European extrusion customers in 2024.[23]
  • 75% of Atessa’s planned recycled low-carbon aluminium output was intended to replace current sales volume from refurbishment projects.[23]
  • 11 extrusion presses operated at Hydro’s Cressona site, including a new 3,000-tonne indirect press opened in 2024.[23]

Mergers and acquisitions in the extrusion industry

  • One North American extrusion company, Team Pride Extrusions, was acquired by Republic Strategic Investments in 2024.[25]
  • One casting and hot-rolling facility in Shandong, China, was acquired by Gränges from Shandong Innovation Group in October 2024.[26]
  • 100% of Alu Menziken Extrusion AG was acquired by Mengtai Germany GmbH from Montana Aerospace in 2024.[27]
  • One production company, GETEK GmbH, was established by Gränges and Erbslöh Aluminium through a joint investment in 2017.[26]

Strategic partnerships in the extrusion industry

  • Three customer-partnership packages were structured by Hydro Extrusions Europe in 2024 to support sustainability goals.[23]
  • One industry-science partnership was cited by Hydro in 2025 as supporting faster translation of innovation from laboratory to production.[23]
  • 22 recycling facilities were operated by Hydro Extrusions across Europe, North America and South America in 2024.[23]
  • Four Hydro Extrusions business units managed value chains from recycling and extrusion through value-added operations, product development and sales in 2024.[23]
  • More than 50% was the year-on-year increase in Hydro’s sales by value of lower-carbon-footprint products in 2025.[23]
  • Two parties—Gränges and Shandong Innovation Group—formed the strategic relationship associated with Gränges’ 2024 Chinese facility acquisition.[26]

07 Statistics

People & Workforce

Workforce indicators include 60,840 people in the U.S. metal-and-plastic extruding and drawing setter/operator/tender occupation, plus 205 extrusion technician job postings. Training timelines for aluminum-extrusion apprenticeships run 2 years.

Hiring in the extrusion industry

  • 176 recent U.S. job postings listed operator as a title in the extrusion-related occupation data.[3]
  • 11 aluminum-extrusion locations operated by six companies had received approval for the AEC apprenticeship initiative between late 2024 and 2025.[25]
  • 90 recent U.S. job postings listed extrusion manager as a title in the extrusion-related occupation data.[3]
  • 9 active apprentices were participating in the Aluminum Extruders Council’s North American extrusion workforce initiative between late 2024 and 2025.[25]
  • About 20 aluminum-extrusion companies were working with AEC to establish press-operator and die-technician apprenticeships.[28]

Employee retention in the extrusion industry

  • 6 to 9 months was the typical time required to move an aluminum-extrusion apprenticeship location from initial engagement to an active program.[25]
  • 3 to 6 months was Engineered Profiles’ initial target for taking a new employee with no extrusion experience to independent production-line operation.[29]
  • 80% of Extrudex’s aluminum-extrusion workforce was described by the company as nonskilled under industry classification, despite receiving in-house training.[30]

Remote Work in the industrial manufacturing sector (sector benchmark)

  • Across U.S. manufacturing, 19% of workers worked remotely, including hybrid and fully remote arrangements, during October 2023–September 2024.[31]
  • Across U.S. manufacturing, 36.9% of workers could work at home and 33.3% actually did so during 2024–2025.[32]
  • Across U.S. manufacturing, teleworked hours represented 12.2% of total hours worked in 2025.[32]
  • Across U.S. manufacturing, 35.2% of surveyed workers reported remote work in the Chicago Fed Survey of Economic Conditions from July 2021 through March 2024.[33]

Hybrid Work in the industrial manufacturing sector (sector benchmark)

  • Across manufacturing employers, 67% identified productivity as a key factor driving pressure to return to the office in 2025.[34]
  • Across manufacturing employees, 80% believed office mandates reflected a lack of trust that employees would be productive at home in 2025.[34]
  • Across manufacturing companies, 79% operated a hybrid model for non-production employees in 2025.[35]
  • Across manufacturing companies, 17% were fully back in the office for non-production employees in 2025.[35]
  • Across manufacturing companies, the average required office attendance reached 2.82 days per week in the second quarter of 2025.[35]

Upskilling in the extrusion industry

  • $8,000 was invested in workforce training by Fabricated Extrusion in 2025, supporting leadership development and technical capability.[36]
  • 2,000 hours of on-the-job training per year are required in the AEC industrial-maintenance-technician apprenticeship for aluminum-extrusion employees.[25]
  • 2 years is the duration of the AEC industrial-maintenance-technician apprenticeship for North American aluminum-extrusion workers.[37]
  • 2 years is the planned duration of the AEC aluminum-extrusion press-operator apprenticeship.[25]
  • 1 employee at Fabricated Extrusion was supported through a Tooling University tool-and-die-maker apprenticeship as part of the company’s 2025 workforce-upskilling initiative.[36]

Employee Engagement in the industrial manufacturing sector (sector benchmark)

  • Across manufacturing, distribution and storage organizations, the average employee-engagement score was 72.9% in 2026.[38]
  • Across manufacturing companies, 25% of respondents did not know whether their frontline workforce was engaged in 2023.[7]
  • Across manufacturing companies, 70% of respondents said most non-frontline employees were engaged in their jobs in 2023.[7]
  • Across manufacturing companies, 41% identified employee recognition as a high priority in 2024.[39]
  • Across manufacturing companies, 48% of respondents said most frontline workers were engaged in their jobs in 2023.[7]

DEI in the extrusion industry

  • 20.4% of the U.S. extruding, forming, pressing and compacting machine-setter, operator and tender workforce were women in 2024.[40]
  • 5,257 women were represented in the U.S. extruding, forming, pressing and compacting machine-setter, operator and tender workforce in 2024.[40]
  • 79.6% of the U.S. extruding, forming, pressing and compacting machine-setter, operator and tender workforce were men in 2024.[40]

08 Statistics

Customer & Sales

Delivery performance and customer duration are used as comparability points, including Hydro Extruded Solutions on-time delivery at 93% across 2023. Customer tenure is also measured, such as 12.5 years average for top Plastic customers.

Customer experience in the extrusion industry

  • 90% was Hydro Extruded Solutions’ on-time delivery rate in 2022 across its extrusion business.[41]
  • 93% was Hydro Extruded Solutions’ on-time delivery rate in 2020 across its extrusion business.[41]
  • 1st place was Hydro’s ranking among competitors in its 2023 aluminium customer-satisfaction study.[41]
  • 93% was Hydro Extruded Solutions’ on-time delivery rate in 2023 across its extrusion business.[41]
  • More than 100 participants contributed to Hydro’s customer-satisfaction study covering aluminium customers and internal extrusion customers.[41]

Customer retention in the extrusion industry

  • Over 50 years of operating history is cited by Pexco while serving industrial and commercial extrusion customers.[42]
  • Nearly 39 years of extrusion-industry experience is reported by Rajoo Engineers in its 2024–2025 annual report.[43]
  • 18 of Plastic’s top 20 customers had purchased from the company for at least five years.[44]
  • Over 35 years of expertise in custom plastic extrusion profiles are reported by Vidon Plastics.[45]
  • 12.5 years was the average relationship length among Plastic’s top 20 customers.[44]

Customer acquisition in the extrusion industry

  • 1,000+ active customers are served by Pexco across industrial and commercial markets in the United States and Mexico.[42]
  • 700+ customers in more than 110 countries are reported by American Extrusion International.[46]
  • 400+ active customers are served by Carolina Extruded Plastics in Greensboro, North Carolina.[47]
  • 70 countries are served by Rajoo Engineers through its global extrusion-machinery customer base.[43]
  • 19,000+ people were on the AEC Buyers’ Guide mailing list in the 2025 media guide.[48]

Customer loyalty in the extrusion industry

  • 15 years was the relationship length for seven of Plastic’s top customers.[44]
  • 3 years was the relationship length for one of Plastic’s top customers.[44]
  • 20 years was the relationship length for two of Plastic’s top customers.[44]
  • 5 years was the relationship length for two of Plastic’s top customers.[44]
  • 10 years was the relationship length for six of Plastic’s top customers.[44]

Lead generation in the extrusion industry

  • 7,500+ cumulative webinar registrants were reported by AEC in its 2019 media guide.[49]
  • 4,800+ cumulative webinar attendees were reported by AEC in its 2019 media guide.[49]
  • 12,595+ cumulative registrants had enrolled in AEC webinars by the 2025 media guide.[48]
  • 12,000 people were on the AEC mailing list in its 2019 media guide.[49]
  • 10,000 recipients were included in AEC webinar email distribution in the 2025 media guide.[48]

09 Statistics

Marketing & Brand

AEC Buyers’ Guide demand indicators include 11,675 page views in the 2025 media guide. Webinar reach is tracked with 8,300+ cumulative attendees reported for AEC webinars.

Marketing in the extrusion industry

  • 12,595+ cumulative webinar registrants were available to sponsors as prospective extrusion-industry contacts.[48]
  • 8,300+ cumulative webinar attendees were reported as an audience for AEC promotional marketing.[48]
  • 11,675 page views were recorded for the AEC Buyers’ Guide in the 2025 media guide.[48]
  • 31% year-over-year growth was reported for AEC.org monthly page views in the 2019 media guide.[49]
  • 21,000+ monthly page views were reported for AEC.org in the 2019 media guide.[49]

Digital marketing in the extrusion industry

  • 21,000+ monthly page views were recorded by AEC.org during the cited 2017–2018 analytics period.[49]
  • 6,346 annual visits were recorded for AEC’s Extrusion Process page.[49]
  • 6,100+ monthly visits were recorded by AEC.org during the cited 2017–2018 analytics period.[49]
  • 4,491 annual visits were recorded for AEC’s Aluminum Extrusion Manual page.[49]
  • 87% of AEC website visitors were new visitors during the cited 2017–2018 analytics period.[49]

Branding in the extrusion industry

  • 12,595+ cumulative registrants represented the audience available for AEC webinar sponsorship and brand exposure.[48]
  • 8,300+ cumulative attendees represented the audience reached by AEC webinars for extrusion-related brands.[48]
  • 12,000+ contacts were on the AEC mailing list in the 2019 media guide.[49]
  • 7,500+ cumulative AEC webinar registrants were reported as a potential branding audience in 2019.[49]
  • 16,000 webinar page views were reported by AEC as an audience for sponsored extrusion-industry content.[49]

Influencer Marketing in the industrial manufacturing sector (sector benchmark)

  • Across B2B companies, 43% of marketers planned to increase influencer investment in the following year in 2025; global survey scope.[50]
  • Across B2B companies, 76% of marketing leaders said creator collaboration helps build brand authenticity in 2025; global survey scope.[50]
  • Among manufacturing marketers using paid channels, 19% used influencer marketing in the 12 months covered by the 2025 outlook survey; global manufacturing, survey conducted June–August 2024.[51]
  • Across B2B companies, 55% of marketers used influencers in 2025, providing a benchmark applicable to industrial manufacturing marketers.[50]
  • Across B2B companies, 29% of marketers planned to adopt influencer marketing within the following year in 2025; global survey scope.[50]

10 Statistics

Operations & Execution

Execution metrics show measurable gains, such as 210 kg/h improved extrusion productivity and waste falling to 2.5% in an industrial case study. Energy change is also quantified, including a 39.14% energy-saving ratio in 2025.

Process optimization in the extrusion industry

  • 210 kg/h was the improved extrusion productivity rate in an industrial case study, compared with 60–70 kg/h for the existing system in 2025.[52]
  • 2.5% was the waste rate of the improved extrusion system, compared with approximately 10% for the existing system in 2025.[52]
  • 39.14% was the annual energy-saving ratio reported after process improvements at a polyethylene-film extrusion operation in 2025.[52]
  • 1,764 MWh of energy was saved through EPL Global’s energy-reduction initiatives in fiscal year 2023–24, including manufacturing-process improvements.[53]
  • 0.3601 MWh/t was ALRO’s post-improvement specific electricity consumption for the extrusion measure, down from 0.3612 MWh/t in 2024.[54]

Operational efficiency in the extrusion industry

  • 139.152 million pounds was Tube Group’s aluminium-extrusion sales volume in 2024, up 0.5% from 2023.[55]
  • 67,790 tonnes was Capral’s extrusion sales volume in 2024, down 4.6% from 71,060 tonnes in 2023.[56]
  • 17.862 million dollars was Tube Group’s aluminium-extrusion capital expenditure in 2024.[55]
  • 34,276 kWh was the monthly electricity consumption of four extrusion-machine heaters before EPL Global’s cast-aluminium-heater upgrade in fiscal year 2023–24.[53]
  • 140 production sites and offices in 40 countries comprise Hydro Extrusions’ global operating footprint.[23]

Supply chain in the extrusion industry

  • 46% of Rio Tinto’s primary aluminium sales were value-added products in 2024, with average product premiums of $295 per tonne.[55]
  • 5 extrusion plants in Europe were proposed for closure by Hydro as part of restructuring plans announced for 2026.[23]
  • $2,834 per tonne was Rio Tinto’s average realised aluminium price in 2024, 4% higher than in 2023.[55]
  • $295 per tonne was Rio Tinto’s average value-added-product premium in 2024, compared with $354 per tonne in 2023.[55]
  • 40 countries contain Hydro Extrusions’ production sites and offices, supporting its international extrusion supply network in 2024.[23]

Outsourcing / Offshoring in the industrial manufacturing sector (sector benchmark)

  • Across global manufacturing, executives expected offshore facilities to decline to 28% within three years of 2025, while onshore facilities rise to 48%.[57]
  • Across global manufacturing, 73% of executives in 2025 believed friendshoring would represent a significant share of future sourcing and production.[57]
  • Across global manufacturing, 56% of executives in 2025 said their organization had invested in nearshoring or a combination of reshoring and nearshoring.[57]
  • Across global manufacturing, 37% of facilities were offshore in 2024, compared with 41% onshore and 22% nearshore.[57]
  • Across EU enterprises sourcing abroad during 2021–2023, 39% outsourced business functions to external providers, while 72% used affiliated enterprises abroad for insourcing.[10]

11 Statistics

Finance & Pricing

Price exposure remains tied to input costs, trade measures, and product mix, with capacity utilization falling from 83.5% in 2021 to 70.1% in 2023 in a U.S. aluminium extrusion investigation. Company pricing examples include Kaiser’s $2.58 per pound realized selling price in 2024.

Pricing strategy in the extrusion industry

  • 4% was Capral’s increase in average selling prices in 2024, driven by higher global aluminium prices.[56]
  • $471.815 million was Tube Group’s aluminium-extrusion net sales in 2024, down 0.6% from 2023.[55]
  • 5.8% was Tube Group’s year-on-year increase in third-quarter 2024 aluminium-extrusion net sales, primarily reflecting higher volume and metal-cost pass-through.[55]
  • $2,834 per tonne was Rio Tinto’s average realised aluminium price in 2024, up 4% year on year.[55]
  • $2.58 per pound was Kaiser Aluminum’s average realised selling price in 2024, unchanged from 2023.[58]

Cost reduction in the extrusion industry

  • 906,019 kWh per year was the energy saving reported after improvements to an extrusion operation in 2025.[52]
  • 10% was the forming-scrap reduction modeled for North American aluminium extrusion, producing the estimated annual savings of $270 million to $311 million.[59]
  • $270 million to $311 million per year is the estimated saving for North American aluminium extruders from reducing forming scrap by 10%.[59]
  • 150,000 RMB per year was the saving from EPL Global’s extrusion-heater upgrade in fiscal year 2023–24.[53]
  • 39.14% was the energy-saving ratio achieved after the extrusion-process improvement in 2025.[52]

Profitability in the extrusion industry

  • $18.232 million was Tube Group’s aluminium-extrusion EBIT from ongoing operations in 2024, up 9.1% from 2023.[55]
  • $3.673 billion was Rio Tinto’s underlying aluminium EBITDA in 2024, up 61% from 2023.[55]
  • $32.5 million was Capral’s net profit after tax in 2024, compared with $31.8 million in 2023.[56]
  • 30% was Rio Tinto’s underlying EBITDA margin for integrated aluminium operations in 2024, versus 21% in 2023.[55]
  • 10% was Rio Tinto’s underlying return on capital employed for aluminium in 2024, compared with 3% in 2023.[55]

Financial planning in the extrusion industry

  • $1.694 billion was Rio Tinto’s 2024 aluminium capital expenditure excluding equity-accounted units.[55]
  • $52.7 million was Capral’s operating cash flow in 2024, compared with $75.0 million in 2023.[56]
  • NOK 8–10 billion is Hydro’s revised 2030 EBITDA target for Extrusions announced in 2025.[23]
  • $17.862 million was Tube Group’s aluminium-extrusion capital expenditure in 2024.[55]
  • $68.9 million was Capral’s net cash balance at the end of 2024, compared with $59.5 million in 2023.[56]

12 Statistics

Product & Service

Digital maintenance and manufacturing lead times are tracked for extrusion supply chains, including 10,000+ aluminium extrusion dies maintained with digital records in 2026 and 5–7 days typical lead time for mill-finish profiles.

Product lifecycle in the extrusion industry

  • 10,000-plus aluminium extrusion dies were maintained with digital records at SYHARVEST’s Foshan plant in 2026.[19]
  • 20-plus CNC machining centres supported the extrusion plant’s downstream processing in Foshan in 2026.[19]
  • 5–7 days was SYHARV’s typical lead time for mill-finish aluminium profiles in 2026.[19]
  • About 12 days was SYHARV’s typical lead time for aluminium profiles with surface treatment in 2026.[19]
  • 8 extrusion presses, ranging from 660 to 4,000 tonnes, operated at SYHARV’s Foshan plant in 2026.[19]

Value proposition in the extrusion industry

  • 2.4 million short tons valued at $14.9 billion represented apparent U.S. aluminium-extrusion consumption in 2022.[60]
  • 53.4% of apparent U.S. aluminium-extrusion consumption by quantity came from U.S. producers’ shipments in 2022.[60]

13 Statistics

Sustainability & Ethics

Circular-content requirements are backed by audited material inputs, including 100% post-consumer scrap used in Hydro CIRCAL 100R launched for extrusion and design applications in 2024. Hydro also reported 27% reduction in European aluminium extrusion energy consumption versus 2015.

Sustainability in the extrusion industry

  • 30 facilities and 100 extrusion presses in the United States and Canada were covered by the Aluminum Extruders Council’s 2022 industry-average EPDs.[37]
  • 50 product configurations were analyzed by Hydro Extrusion North America in its 2024 environmental study.[23]
  • 22 Hydro Extrusion North America manufacturing sites were included in site-specific environmental studies published in 2024.[23]
  • 33 individual environmental product declarations were published by Hydro Extrusion North America in 2024.[23]
  • 40,000 tonnes was the planned annual recycling capacity of Hydro’s upgraded Atessa extrusion plant in Italy.[23]

ESG in the extrusion industry

  • 47 Hydro Extrusions sites were ASI-certified, embedding environmental, social and human-rights requirements across the extrusion business in 2022.[23]
  • 75% is the minimum post-consumer recycled aluminium content in Hydro CIRCAL material used for extrusion components.[23]
  • 82.1% post-consumer scrap was specified in Hydro’s 75R extrusion ingot EPD.[23]
  • 100% post-consumer scrap was used in Hydro CIRCAL 100R aluminium launched for extrusion and design applications in 2024.[23]
  • 47% prime and 53% recycled aluminium was the average billet composition used in the Aluminum Extruders Council’s 2022 LCA.[37]

Circular economy in the extrusion industry

  • 90% was the approximate reduction in transport-related emissions achieved by Hydro’s 100-kilometre-radius recycled-aluminium project.[23]
  • 75% is the minimum post-consumer scrap content of Hydro 75R extrusion ingot.[23]
  • 52 tonnes of scrap from decommissioned greenhouses and light poles were used in Hydro’s Benelux recycled-aluminium project.[23]
  • 25,000 tonnes of additional Hydro 75R extrusion ingot capacity was planned from the Azuqueca investment for 2020.[23]
  • 120,000 tonnes was the annual extrusion-ingot capacity of Hydro’s recycling plant opened in November 2023.[23]

Carbon footprint in the extrusion industry

  • 25% or less of the A1–A3 footprint came from extrusion processing for standard mill-finish aluminium extrusions in the Aluminum Extruders Council LCA.[37]
  • 33% or less of the A1–A3 footprint came from extrusion, painting and thermal processing for thermally enhanced painted extrusions in the Aluminum Extruders Council LCA.[37]
  • 27% was the reduction in total energy consumption of the European aluminium extrusion process compared with 2015.[61]
  • 11.29 tCO2e per tonne was Capral’s weighted-average emissions intensity for aluminium billet procurement in 2024.[62]
  • 8% was the decline in greenhouse-gas emissions from North American aluminum extrusion between 2010 and 2016.[37]

15 Statistics

Globalization & Expansion

Aluminium extrusion footprint data shows regional networks and scale, such as Hydro’s 70 production sites in 20 countries in 2024. Market share examples include Hydro estimated 19% in North America in 2024 and 16% in Europe in 2024.

Globalization in the extrusion industry

  • 31.5 million tonnes was estimated global aluminium extrusion usage in 2023.[25]
  • 19% was Hydro Extrusions’ estimated aluminium extrusion market share in North America in 2024.[23]
  • 14 countries were covered by the United States’ 2024 antidumping and countervailing-duty investigation of aluminium extrusions.[60]
  • 70 production sites in 20 countries comprised Hydro Extrusions’ global aluminium extrusion and recycling network in 2024.[23]
  • 16% was Hydro Extrusions’ estimated aluminium extrusion market share in Europe in 2024.[23]

Supplier management in the extrusion industry

  • 30,000 tonnes was the increase in post-consumer scrap processing capacity from Hydro’s Cressona, Pennsylvania, recycling expansion.[23]
  • Two procurement arrangements—open-market purchases and annual contracts—were used for Tredegar’s aluminium extrusion raw materials in 2024.[55]
  • 140,000 tonnes of annual recycling capacity was added by Hydro Extrusions’ 2024 projects in Europe and North America.[23]
  • Three principal raw-material categories—aluminium ingot, aluminium scrap and various alloys—were purchased by Tredegar’s Aluminium Extrusions segment in 2024.[55]
  • 20,000 tonnes of Hydro’s upgraded 40,000-tonne annual recycling capacity in Atessa, Italy, was designed for recycled low-carbon aluminium made from post-consumer scrap.[23]

Stakeholder management in the extrusion industry

  • 33,000 employees worked for Hydro across more than 140 locations in 2024.[23]
  • Five European extrusion plants were proposed for closure by Hydro during 2026 as part of restructuring.[23]
  • 1.0 million tonnes was Hydro Extrusions’ sales volume in 2024.[23]
  • 28 production sites and approximately 7,000 employees represented Hydro’s North American aluminium operations in 2024.[23]
  • 1,100 employees worked at Hydro’s Cressona, Pennsylvania, extrusion and recycling site in 2024.[23]

Distribution channels in the extrusion industry

  • 16% of Kaiser Aluminum’s net sales came from its largest customer in both 2025 and 2024.[55]
  • 11 extrusion presses and one distribution warehouse operated at Hydro’s Cressona, Pennsylvania, site in 2024.[23]
  • 1,000 customers were served by Hydro’s Nenzing extrusion plant, mainly in German-speaking countries.[23]
  • 30% of Kaiser Aluminum’s shipments went to metal service centers in 2025.[55]
  • 70% of Kaiser Aluminum’s shipments went directly to manufacturers or tier-one suppliers in 2025.[55]

Key questions about the Extrusion Industry

What is the market size for plastics extrusion in 2025 and 2026?
The global plastics extrusion market was $238.99 billion in 2025 and $254.04 billion in 2026.
How fast is the plastics extrusion market growing from 2026 to 2030?
The plastics extrusion market is forecast to reach $319.21 billion by 2030, at a 5.9% CAGR from 2026 onward.
Which companies lead the extrusion industry?
Hindalco Industries leads Gitnux's 2026 extrusion ranking with an Overall score of 9.8, with 90 kilotonnes of aluminum extrusion production in FY2025-26. REHAU Group is the highest-ranked polymer profile extruder at 9.1, with extrusion used to produce polymer profiles, tubing and seals for construction and industrial markets.
What AI and automation shifts are being projected for extrusion operations?
By end of 2028, 7% of working time for U.S. metal-and-plastic extruding and drawing machine operators is projected to be technically automatable by AI. In 2026, 6% of working time could be performed by current AI models, per a task-level assessment.
How concentrated is aluminium extrusion, and what drives demand?
Aluminium extrusion remains regionally concentrated and increasingly tied to recycling and low-carbon demand, while Hydro reported 69 production sites in 20 countries with 1.4 million tonnes annual capacity.
How do regulations affect material and operations for extrusion-heavy supply chains?
EU Packaging and Packaging Waste Regulation entered into force February 11, 2025 and applies from August 12, 2026; from 2030 it requires recycled content in plastic packaging (including 30% for PET contact-sensitive packaging).
Reference

Cite This Report

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APA
Megan Gallagher. (2026, February 13). Extrusion Industry Statistics. Gitnux. https://gitnux.org/extrusion-industry-statistics
MLA
Megan Gallagher. "Extrusion Industry Statistics." Gitnux, 13 Feb 2026, https://gitnux.org/extrusion-industry-statistics.
Chicago
Megan Gallagher. 2026. "Extrusion Industry Statistics." Gitnux. https://gitnux.org/extrusion-industry-statistics.

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