North America Plastic Extrusion Measurement and Control Technology Market Size - By Measurement Principle, By Integration Level, By Control Technology Type, By Application, By End Use Industry & Forecast, 2025 – 2034

North America Plastic Extrusion Measurement and Control Technology Market Size

The North America plastic extrusion measurement and control technology market was estimated at USD 245.4 billion in 2024. The market is expected to grow from USD 270.2 billion in 2025 to USD 410.2 billion in 2034, at a CAGR of 4.7% according to latest report published by Global Market Insights Inc.

• The North American market growing steadily due to the growth of infrastructure modernization projects at the scale being built across the U.S. and Canada. The construction, utility and transportation sectors depend on extruded plastics for pipes, profiles and sheets of plastic used in their industry. These industries rely on advanced technology for the displacement of material and establishing high quality and efficiency of production by implementing precision control and measuring systems that conform to very strict requirements when producing these items.
   
• The increasing need for packaging and food and beverage production is also contributing to continued market growth. Urbanization and an increase in the number of people consuming packaged goods creates an increase in the amount of film, sheet and coating products produced using extrusion methods. Inline measurement and automated control systems are mandatory when producing these products, in order to meet regulatory standards related to film thickness, barrier properties and film uniformity. Inline measurement and control also allow manufacturers to significantly reduce waste of raw materials and achieve greater output speeds.
   
• The shipment of products through the North American region is undergoing significant changes as a result of the emergence of Industry 4.0 technologies. IoT-enabled sensors, cloud-based computing, AI-based analytics and closed-loop production control systems provide real-time monitoring and predictive maintenance of equipment, and thus improve the overall productivity of the extrusion industry. These technologies help to eliminate unexpected equipment downtime due to equipment failure, and also provide a solution to the labour shortages by automating many of the more complex and repetitive tasks that would otherwise be required by a manufacturer to produce high-quality products and grow strategically.
   
• There is an increasing demand for fully automated plastic extrusion facilities. Advanced measurement and control solutions combined with automation enable manufacturers to reduce human error, save time, and improve overall efficiency. In fact, smart technologies will play a key role in future developments by enabling businesses to manufacture superior quality products at lower costs than traditional methods.
   

North America Plastic Extrusion Measurement and Control Technology Market Trends

• The plastic extrusion sector in North America is currently navigating a challenging landscape characterized by rising labor costs, reshoring efforts, and increasingly stringent quality expectations. A significant trend shaping the industry is the shift from traditional manual and offline quality checks to advanced, fully inline, closed-loop measurement and control systems. Processors are progressively adopting cutting-edge technologies, including laser, ultrasonic, X-ray, and optical gauges, which are installed directly on production lines. These systems provide continuous monitoring of critical parameters such as wall thickness, diameter, and profile geometry. The data generated is seamlessly integrated into extruder and downstream control systems, enabling automatic adjustments to line speed, melt pressure, and die settings.
   
• Another pivotal trend in the North American plastic extrusion market is the increasing use of advanced measurement and control technologies to drive sustainability and optimize raw-material efficiency. With prices remaining high and growing regulatory and consumer pressure to incorporate recycled and bio-based materials, processors are focusing on tightening tolerances to minimize plastic overuse. State-of-the-art thickness and weight-control systems are being deployed to "lightweight" products, maintain consistent gauge even when using variable-quality recyclate, and document material savings for Environmental, Social, and Governance (ESG) reporting. These advancements not only improve profit margins in a cost-sensitive market but also align with corporate sustainability goals and regulatory requirements aimed at reducing waste and carbon emissions. By adopting these technologies, manufacturers are better positioned to meet the dual objectives of economic efficiency and environmental responsibility.
   
• Aligned with the broader adoption of Industry 4.0 principles, the North American extrusion market is rapidly embracing IoT-enabled, data-rich measurement systems and advanced analytics powered by artificial intelligence (AI). Sensors and gauges are increasingly networked, streaming real-time process and quality data to on-premise or cloud-based analytics platforms. Manufacturers leverage this data for statistical process control, real-time Key Performance Indicator (KPI) monitoring, and predictive maintenance. By identifying patterns indicative of potential issues such as screw wear, die build-up, or cooling inefficiencies, these systems enable proactive interventions that prevent scrap generation and production downtime.
   
• Another trend in the North American plastic extrusion sector is the growing preference for retrofitting and modernizing existing extrusion lines rather than investing in complete replacements. Many processors are operating legacy equipment but are upgrading these lines with advanced sensors, control software, and communication modules to extend their operational life and bring them up to current performance standards. Modular and brand-agnostic retrofit kits are in high demand, as they allow processors to incrementally add capabilities such as automatic wall-thickness control, profile measurement, and inline defect detection. By adopting this strategy, manufacturers can remain competitive in a rapidly evolving market while optimizing their return on investment.
   

North America Plastic Extrusion Measurement and Control Technology Market Analysis

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Based on integration level, the market is categorized into manual operation level, basic automation level, advanced automation level, and intelligent automation level. The basic automation level accounted for revenue of around USD 120.1 billion in 2024 and is anticipated to grow at a CAGR of 5% from 2025 to 2034.
 

• Many regional processors face budget constraints and lack the technical expertise required for advanced or intelligent automation systems, making basic automation an attractive entry point. This level typically includes semi-automated controls, simple sensors, and programmable logic controllers (PLCs) that significantly improve process consistency and reduce human error without requiring heavy investment or complex infrastructure upgrades.
   
• Additionally, rising labor shortages and the need for operational efficiency are pushing companies to adopt affordable automation solutions that deliver measurable productivity gains. Basic automation also aligns well with the growing demand for standardized quality in packaging, construction, and consumer goods sectors, where extrusion processes must meet tighter tolerances.
   

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Based on control technology type, the North America plastic extrusion measurement and control technology market consists of process control systems, motion and drive control systems, material flow control systems, control hardware and platforms. The process control systems emerged as leader and held 41.9% of the total market share in 2024 and is anticipated to grow at a CAGR of 5.2% from 2025 to 2034.
 

• Rapid urbanization, changing lifestyles, and the growth of e-commerce have significantly increased the consumption of flexible packaging, films, and sheets, all of which rely heavily on extrusion processes. These applications require precise thickness control, uniformity, and barrier properties to ensure product safety and compliance with food-grade standards, making advanced measurement and control systems indispensable.
   
• Additionally, the trend toward sustainable packaging such as recyclable mono-material films and bio-based plastics has introduced greater complexity in extrusion operations, further driving the need for accurate monitoring and automated adjustments.
   

Based on application of North America plastic extrusion measurement and control technology market consists of pipe and tube extrusion, profile extrusion, cable and wire extrusion, and film and sheet extrusion. The pipe and tube extrusion emerged as leader and held 32% of the total market share in 2024 and is anticipated to grow at a CAGR of 4.7% from 2025 to 2034.
 

• Large-scale investments in water supply networks, sewage systems, irrigation projects, and gas distribution pipelines are driving demand for high-quality plastic pipes and tubes. These applications require precise dimensional control and consistent wall thickness to ensure durability, safety, and compliance with stringent regulatory standards, making advanced measurement and control systems essential.
   
• Additionally, the shift toward lightweight, corrosion-resistant plastic alternatives over traditional metal pipes in construction and industrial sectors further boosts extrusion volumes. The growing emphasis on sustainability and cost efficiency also encourages the use of recycled and composite materials in pipe production, which necessitates accurate process monitoring to handle material variability.
   

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The U.S. dominates an overall North America plastic extrusion measurement and control technology market and valued at USD 208.9 billion in 2024 and is estimated to grow at a CAGR of 4.7% from 2025 to 2034.
 

• The U.S. plastic extrusion market is undergoing a significant transformation, driven by advancements in automation, precision engineering, and sustainability-focused initiatives. Manufacturers are increasingly integrating advanced measurement and control systems into extrusion lines to achieve tighter tolerances, reduce material waste, and enable real-time performance monitoring. This shift aligns with the broader adoption of Industry 4.0 principles, where IoT-enabled sensors, machine learning, and predictive analytics are optimizing throughput, energy efficiency, and overall operational performance. These technologies are not only enhancing production capabilities but also providing manufacturers with actionable insights to improve decision-making and maintain competitive advantages.
   
• The demand for such innovations is particularly strong in key sectors such as packaging, automotive, and construction, where the production of high-quality profiles and complex designs requires precise extrusion control and advanced manufacturing techniques. Furthermore, government incentives and strategic industry collaborations are accelerating the pace of modernization.
   

North America Plastic Extrusion Measurement and Control Technology Market Share

• In 2024, the prominent manufacturers in North America plastic extrusion measurement and control technology industry are Nordson Corporation, Dynisco, Process Control Corp, Gefran Tempco, and PTI collectively held the market share of ~50.3%.
   
• Nordson leverages its Ascend strategy and "NBS Next" framework to boost innovation, enhance customer responsiveness, and trim lead times. A testament to this is Nordson's launch of the Quadra Pro X-ray inspection system, which went from concept to market in under a year, slashing the typical six-month lead time down to just two weeks. Beyond innovation, Nordson strategically acquired Atrion Medical to bolster its foothold in burgeoning sectors like medical devices and electric vehicle battery production. Committed to digital transformation, Nordson is broadening its global footprint and harnessing automation to elevate both efficiency and customer experience.
   
• Dynisco carves its niche in precision polymer sensing and testing, offering tools like melt-flow indexers and pressure sensors for real-time quality oversight. At its bioplastics Innovation Lab, the company pioneers sustainable materials and eco-conscious resin processing. By embedding IoT and Industry 4.0 technologies, Dynisco facilitates remote diagnostics and process monitoring. With a strong emphasis on intellectual property and patent development, Dynisco solidifies its leadership in advanced sensing technologies, while its lean operations ensure swift market adaptability.
   

North America Plastic Extrusion Measurement and Control Technology Market Companies

Major players operating in the North America plastic extrusion measurement and control technology industry include:

• Bausano
• Breyer
• Dynisco
• Gefran 
• Gemini Group
• Nanmac
• Nordson Corporation 
• Pexco
• Process Control Corp.
• PTI
• Pyrometer Instrument 
• Sensonetics
• Starrett 
• Tempco Electric Heater
• Gneuss Kunststofftechnik GmbH
   

PCC stands out with its high-precision gravimetric blending systems and the proprietary Gravitrol control software, ensuring top-notch extrusion accuracy and minimized material waste. Embracing Industry 4.0, PCC integrates IoT, smart sensors, and predictive maintenance into its machinery for heightened production efficiency. The company champions sustainability with features like automatic scrap recycling and energy-efficient conveyors. Through advanced automation and real-time feedback, PCC guarantees consistent quality and cost savings for its clients.
 

Gefran pushes boundaries with its GRC series smart power controllers, boasting Ethernet connectivity and modular designs tailored for industrial heating. These controllers, aligning with Industry 4.0, offer seamless web server configurations.
 

Tempco Electric Heater specializes in bespoke heating solutions, from band and cartridge heaters to advanced TEC controllers. Both companies emphasize tailored designs and ongoing technical education, solidifying their status as trusted leaders in industrial thermal management.
 

North America Plastic Extrusion Measurement and Control Technology Industry News

• In 2025, Leistritz unveiled its Inline Elongational Rheometer, designed to gauge extensional viscosity during extrusion. This measurement is crucial for film and fiber production, where elongational flow plays a pivotal role. The new tool offers superior data compared to traditional systems, enabling manufacturers to fine-tune processes for enhanced performance.
   
• In 2025, iNOEX launched its WARP radar-based pipe measurement system alongside the promex EXPERT/CYRUS pipe wall inspection systems. Collaborating with optical inspection systems, these tools oversee both the internal and external facets of pipes and profiles, granting manufacturers enhanced oversight of their production processes.
   
• In May 2025, MAAG Group bolstered its digitalization efforts in extrusion process control by acquiring XanTec Steuerungs- und EDV Technik GmbH. Renowned for its advanced control systems tailored for extruders and pelletizing lines, XanTec's offerings promise heightened efficiency and product quality. This strategic acquisition aligns with MAAG’s vision of integrating smart automation and broadening its digital solution portfolio.
   

The North America plastic extrusion measurement and control technology market research report includes in-depth coverage of the industry, with estimates & forecast in terms of revenue (USD Billion) from 2021 to 2034, for the following segments:

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Market, By Measurement Principle

• Optical-based measurement systems
  • Camera/vision-based inspection
  • Laser-based dimensional measurement
  • Advanced spectroscopic analysis
• Radiometric measurement systems
  • X-ray systems
  • Gamma-ray systems
  • Beta-ray systems
• Electromagnetic wave-based measurement
  • Radar-based systems
  • Terahertz systems
• Acoustic-based measurement
  • Ultrasonic systems
  • Acoustic emission monitoring
• Electrical field-based measurement
  • Capacitive sensors
  • Inductive sensors
• Mechanical contact measurement
  • Physical probes and gauges
  • Tactile measurement systems
• Process parameter monitoring
  • Temperature and pressure sensors
  • Melt flow and viscosity measurement
  • Material property analysis

Market, By Integration Level

• Manual operation level
  • Offline measurement with manual adjustment
  • Operator-controlled processes
• Basic automation level
  • Single-parameter closed-loop control
  • Simple measurement-feedback systems
• Advanced automation level
  • Multi-parameter process control
  • Integrated measurement-control systems
• Intelligent automation level
  • AI/ML-driven optimization
  • Digital twin implementation
  • Predictive maintenance integration

Market, By Control Technology Type

• Process control systems
  • Temperature control
  • Pressure control
  • Multi-zone process control integration
• Motion and drive control systems
  • Extruder drive control and variable speed systems
  • Haul-off and winding control
  • Servo-driven positioning and cutting systems
• Material flow control systems
  • Gravimetric and volumetric dosing control
  • Melt pump control and flow regulation
  • Additive and colorant injection control
• Control hardware and platforms
  • Programmable logic controllers (PLCs)
  • SCADA and HMI systems
  • Distributed control systems (DCS)

Market, By Application

• Pipe and tube extrusion
  • Single-layer pipes
  • Multi-layer pipes
  • Specialty/medical tubing
• Profile extrusion
  • Simple profiles (single cavity)
  • Complex profiles (multi-cavity)
  • Co-extruded profiles
• Cable and wire extrusion
  • Power cables
  • Communication cables
  • Specialty cables
• Film and sheet extrusion
  • Monolayer films
  • Multi-layer films
  • Specialty films

Market, By End Use Industry

• Construction and infrastructure
• Automotive and transportation
• Packaging and food contact
• Healthcare and medical
• Electronics and telecommunications
• Others (energy and utilities etc.)

The above information is provided for the following regions and countries:

• North America
  • U.S.
  • Canada