- US Extruders nearly doubled its Westerly, R.I., manufacturing footprint to just over 31,000 square feet after 25–30% year-over-year growth during the pandemic.
- The solar-powered expansion adds cranes, upgraded lab and remote testing capabilities, and more hiring across sales, engineering, and assembly to meet demand.
- Control-supplier partner ProSystems Integration, co-located at the site, expanded its production area by about 40% and anticipated strong sales into 2021.
- The bet on added capacity targets higher-margin, essential end markets even as the broader North American extruder market has recently contracted but is forecast to grow modestly in value long term.
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US Extruders’ expansion is a strategic response to pandemic-induced demand, especially for personal protective equipment and materials used in medical, sheet, pipe, and film extrusions. Their decision to enlarge capacity, invest in infrastructure (cranes, solar power), and sustain remote lab and trial operations positions them advantageously as end-market demand remains volatile but upward-sloping where essential goods and supply-chain resiliency are concerned. ([plasticstoday.com](https://www.plasticstoday.com/extrusion-pipe-profile/us-extruders-nearly-doubles-manufacturing-space?utm_source=openai))
By nearly doubling space and increasing headcount, US Extruders is signaling confidence in sustained demand into 2021. Their solar power alignment and emphasis on made-in-America quality likely improve margins and supply chain control—key advantages given recent cost inflation and import volatility. ([plasticstoday.com](https://www.plasticstoday.com/extrusion-pipe-profile/us-extruders-nearly-doubles-manufacturing-space?utm_source=openai))
However, broader market data suggest caution: Northern America’s extruder market saw a steep consumption volume drop (−58.2%) and market‐value decline (−19.4%) in 2024. While forecast models predict modest unit growth (+0.3% CAGR), value is expected to recover faster (+2.7% CAGR) by 2035. ([indexbox.io](https://www.indexbox.io/blog/plastic-extruder-northern-america-market-overview-2024-4/?utm_source=openai))
This implies that capacity expansions like US Extruders’ must be justified by gaining share in higher-margin segments (e.g., medical, technical resins, PPE), maximizing equipment efficiency, and leveraging vertical integration or partnerships to counteract the lower-unit demand environment. Open questions include how supply chain constraints (raw materials, logistics) and energy/power costs will impact operating leverage, and whether demand in PPE/essential sectors will remain elevated or normalize. Also, how competitors respond will shape pricing and margin dynamics.
Supporting Notes
- US Extruders’ new facility is over 31,000 sq ft and runs entirely on solar power. ([plasticstoday.com](https://www.plasticstoday.com/extrusion-pipe-profile/us-extruders-nearly-doubles-manufacturing-space?utm_source=openai))
- Company is experiencing “unprecedented growth” of 25–30% compared with the previous year. ([plasticstoday.com](https://www.plasticstoday.com/extrusion-pipe-profile/us-extruders-nearly-doubles-manufacturing-space?utm_source=openai))
- Expansion includes overhead cranes, remote testing capabilities, and lab trial infrastructure. ([plasticstoday.com](https://www.plasticstoday.com/extrusion-pipe-profile/us-extruders-nearly-doubles-manufacturing-space?utm_source=openai))
- ProSystems Integration increased its production space by almost 40% in same expansion; projecting record sales in 2020 and better for 2021. ([plasticstoday.com](https://www.plasticstoday.com/extrusion-pipe-profile/us-extruders-nearly-doubles-manufacturing-space?utm_source=openai))
- Northern America’s extruder market contracted to ~25,000 units and US$1.7B value in 2024. ([indexbox.io](https://www.indexbox.io/blog/plastic-extruder-northern-america-market-overview-2024-3/?utm_source=openai))
- The market is forecast to reach ~26,000 units and US$2.3B by 2035, with CAGR about +0.3% (units) and +2.7% (value). ([indexbox.io](https://www.indexbox.io/blog/plastic-extruder-northern-america-market-overview-2024-3/?utm_source=openai))