Plastics industry: plastic extrusion
Plastic extruders, secure the cost of your continuous lines
An extrusion line doesn't stop for the night: every restart costs material, time, and energy. Whether for films, tubes, or profiles, your extruders draw a steady current, and gas heats the halls. Sirenergies helps you purchase the base load for your plastic extrusion at a controlled price and recalibrates your power.
Key industry figures
A continuous process, a permanent base load: energy for extrusion lines
Few workshops consume as consistently as an extrusion plant. This stability has value when purchasing, provided you know the fixed portion of your consumption and don't pay for it at the rate of a small consumer.
Fixed portion of consumption for a profile extrusion site, independent of volume
Electricity price paid by small industrial sites compared to larger ones
Share of fuel consumed by French industry lost as waste heat
The energy profile of a plastic extrusion site
Continuous extruders and a base load that never drops
The situation: flat consumption, almost entirely electrical
On an extrusion line, the motor drives the screw that melts and pushes the material, heating bands keep the barrel at temperature, and then water baths and calibrators cool the film, tube, or profile. An extrusion plant typically consumes 0.4 to 0.6 kWh per kilo processed (Plastics Technology, 2011): less than an injection molding workshop, but continuous. Electricity dominates; gas heats the halls and sometimes process boilers, often under a contract negotiated independently of the electricity contract.
Our role: turning consistency into a purchasing advantage
Your teams and equipment suppliers maintain control over the lines; Sirenergies advises management on three contractual levers.
- The base load: isolated within your load profiles so you can purchase it at a fixed price over several years.
- Transmission: subscribed power and TURPE (public electricity network usage tariff) options, and ATRD (third-party access to gas distribution networks) capacity for facility heating.
- Monitoring: energy cost per extruded kilo, measured at D+1 in Pilott.
Your energy challenges
The 3 energy challenges for plastic extrusion lines
A portion of consumption that runs day and night, prices locked in at the wrong time in the market, and energy costs never calculated per kilo produced: film, tube, and profile extruders all share these three issues. Sirenergies addresses them through procurement, transmission, and data, without needing to intervene on your lines.
Unoptimized continuous consumption
A site that runs 24/7 is fully exposed to market price fluctuations if its contract is not structured accordingly.
Multi-supplier sourcing tailored to base load profiles
Competitive bidding among suppliers for a stable consumption profile, with pricing indexed to the market.
Unrecovered waste heat
ADEME identified 94.3 TWh per year of industrial waste heat in France (2020), with the plastics industry among the sectors involved; a portion remains unrecovered due to a lack of dedicated assessment.
Guidance on recovery studies and procurement support
Technical studies for heat recovery are conducted by specialized thermal engineering firms, which we can help you identify. At the same time, we secure your energy procurement and integrate the resulting savings into your Pilott management system.
Non-consolidated multi-line contracts
Multiple extrusion lines at the same site often lead to fragmented contracts or tracking.
Multi-line audit and centralized management
Pilott centralizes the tracking of all your lines and sites on a single dashboard.
Contractual and data expertise
Optimizing and managing contracts for your plastic extrusion plants
From extruders to the boilers that heat your facilities, Sirenergies supports you with the electricity and gas for your extrusion sites. Your technicians run the lines; we handle what powers them—contracts, transmission, and consumption monitoring, plant by plant.
Contractual and capacity audit
Review of your electricity and gas contracts, their expiration dates, and your subscribed power levels, annual analysis of excise duties, and identification of CEE (Energy Savings Certificate) schemes applicable to your motors and cooling units.
Purchasing strategy and competitive bidding
Consultation with our partner suppliers using specifications that distinguish your continuous base load from the variable portion, clause-by-clause comparison of offers, negotiation prepared and conducted alongside you, and follow-up on price fixing until the expiration date.
Distribution optimization (TURPE / ATRD)
Subscribed power and TURPE options adjusted to a flat, continuous electrical profile, daily ATRD capacity reviewed for facility heating or boilers; we handle the procedures with network operators based on your connection.
Tariff modeling for continuous processes
Budget simulated according to several hedging strategies, analysis of price risks, and the benefits of a PPA (Power Purchase Agreement) to cover long-term consumption that never stops.
Pilott software platform
D+1 consumption for every meter, including nights and scheduled shutdowns, price alerts for electricity and gas, budget forecasting, and centralized contractual documents for all your plants.
Expert consulting dedicated to extrusion
A dedicated consultant who tracks your markets, deadlines, and relevant regulations (excise duties, capacity mechanisms, CEE), and builds energy and budget indicators with you by site and by kilo produced.
Our platform
Pilott, simplified management to track your consumption
- Consolidate your extrusion plants and all their electricity and gas meters
- Check yesterday's consumption at D+1 and identify any increase in your night-time base load
- Get notified when electricity prices hit the threshold set in your strategy
- Forecast your energy budget and manage your contracts on a single platform
Plastics processing
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Methodology and definitions
What is energy consulting for plastic extrusion?
Should you fix the price for consumption that never stops? For a plastic extrusion plant, energy consulting begins with this question: separating the base load of electricity and gas, which is suitable for multi-year fixed pricing, from the variable portion, which can be left indexed to the market or fixed in stages. Sirenergies consultants build this strategy with you and monitor it via the Pilott platform.
The context
In 2024, a tonne of oil equivalent of energy cost rubber and plastic facilities 649 euros, compared to 372 euros in 2019 (Insee Première No. 2095, February 2026). A production line running day and night therefore pays for every price hike across all its operating hours.
Three levers
- A base load purchased at a fixed price, with the variable portion covered according to your risk tolerance.
- Fixing prices over time, prepared using Pilott price alerts.
- Transmission and distribution fees adjusted to the flat profile of your lines, for both electricity and gas.
How much does the base load of your extrusion lines cost you each year?
An analysis of your contracts and load curves is all it takes to isolate it and calculate your margins. No obligation.
