Can PLA Straw Making Machines Produce Different Sizes And Shapes of Straws?

As the global movement toward sustainability gains momentum, PLA (Polylactic Acid) straws have become a favored eco-friendly alternative to traditional plastic straws. Derived from renewable resources like corn starch or sugarcane, PLA straws are biodegradable, compostable, and widely accepted in foodservice, hospitality, and retail sectors. With governments banning single-use plastics and consumers demanding greener solutions, the market for PLA straws has grown rapidly.

However, with increased demand comes the need for product diversity. From bubble tea shops requiring extra-wide straws to juice box manufacturers needing U-shaped or telescopic straws, today’s beverage industry demands customized straw sizes and shapes to meet varied application scenarios. A one-size-fits-all approach is no longer viable. This evolving demand raises a critical question for manufacturers: Can PLA straw making machines produce different sizes and shapes efficiently and at scale?

Common Classifications of Straw Sizes and Shapes

When it comes to PLA straw production, one of the key factors manufacturers must consider is the variety of sizes and shapes required for different end-use applications. Unlike traditional plastic straws, which were often mass-produced in a single format, PLA straws are used across a wide range of industries—each with its own dimensional requirements. Let’s take a closer look at the most common classifications:

1. Diameter (Inner and Outer Widths)

The diameter of a PLA straw directly impacts its usability. Standard diameters range from:

• 3–5 mm: Common for juice boxes, children's beverages, or small-volume drinks.

• 6 mm: The most widely used diameter for soft drinks and everyday beverages.

• 8–12 mm: Popular in bubble tea shops to accommodate tapioca pearls or fruit chunks.

• >12 mm (Jumbo Straws): Used for smoothies, slushies, or specialty drinks with thick textures.

Modern PLA straw making machines—like the LG-A11 series from Sunrise Machinery—allow manufacturers to adjust die heads or change molds to produce multiple diameters using the same base equipment.

2. Length

PLA straws come in different lengths based on the application scenario:

• Short (8–12 cm): Ideal for juice boxes or kid’s drink pouches.

• Medium (15–21 cm): Standard straws used in most commercial beverages.

• Long (22–30+ cm): Suited for tall glasses, bar drinks, or promotional oversized items.

Machine settings—especially cutting length and speed controls—play a key role in producing consistent straw lengths at high throughput rates.

3. Straight vs. Flexible (Bendable) Straws

While straight straws are the most commonly produced, demand for flexible or bendable straws (those with an accordion-style neck) is increasing, particularly in medical, eldercare, and children’s products.

To produce flexible PLA straws, the extruded straight straw must go through an additional bending and corrugation process, often done using secondary forming equipment. Sunrise Machinery provides compatible downstream units that integrate seamlessly with their extrusion lines to support this functionality.

4. Special Shapes: U-Shaped, Telescopic, and Spoon Straws

Certain markets require customized straw shapes such as:

• U-shaped straws: Commonly attached to beverage cartons, requiring heat-set shaping post-extrusion.

• Telescopic straws: Expandable straws for compact packaging, created using multi-stage assembly and telescoping mechanisms.

• Spoon straws: Often used for slush drinks or ice cream floats, made by flattening and shaping the straw’s tip.

These unique straw types can be produced by modifying the post-processing systems attached to the main extrusion machine. With the right configuration, a single production line can accommodate multiple straw formats, reducing operational costs and increasing product diversity.

Flexibility in Machine Adjustment and Die Head Replacement

One of the core advantages of modern PLA straw making machines is their ability to adapt to different product specifications through easy mechanical adjustments and interchangeable die heads. This level of customization is crucial for manufacturers looking to meet varying market demands without investing in separate production lines for each straw size or shape.

1. Modular Die Head Design

Machines like the LG-A11 series from Hangzhou Fuyang Sunrise Machinery Co., Ltd. are engineered with a modular die head system. This design allows operators to quickly switch between different molds—each suited for a specific diameter or straw profile. Whether producing thin juice box straws or thick bubble tea straws, the changeover process is straightforward and efficient.

These die heads are typically made from high-precision alloy steel to ensure durability and maintain strict dimensional tolerances. The ability to swap out die heads in minutes rather than hours significantly reduces downtime and boosts overall productivity.

2. Adjustable Extrusion Settings

Beyond hardware changes, the LG-A11 series also features fully adjustable extrusion parameters:

• Temperature zones along the barrel can be independently controlled to optimize PLA melting behavior.

• Screw speed and pressure settings can be fine-tuned to control the extrusion flow, ensuring smooth and consistent straw walls.

• Cooling water temperature and flow rate are also adjustable to accommodate different straw thicknesses and prevent deformation during shaping.

These settings allow operators to respond to changes in material grade, ambient temperature, or desired output without compromising on quality.

3. Precision Control of Straw Dimensions

Another important factor in straw customization is the ability to precisely control dimensions during production. With advanced mechanical designs, the LG-A11 extrusion line ensures uniform wall thickness, smooth surface finish, and minimal material waste—even when producing straws with complex shapes or variable sizes.

For example, a customer may require a 6mm straw with a 0.3mm wall thickness for carbonated beverages, while another client might request an 8mm thick-walled straw for frozen drinks. Instead of purchasing two separate machines, a single LG-A11 system can fulfill both orders by simply adjusting its settings and die head.

4. Tool-Free Maintenance and Quick Swaps

Ease of maintenance is another benefit of modern PLA straw machinery. The LG-A11 series supports tool-free or low-tool mold changes, using quick-lock mechanisms and standardized fittings. This user-friendly design reduces the skill threshold for machine operation and minimizes human error during maintenance or changeovers.

Operators can complete mold changes, clean the system, and resume production within a short period—enabling multi-batch production runs with different straw specifications on the same day.

Application of Multi-Hole Die Heads and Variable Frequency Cutting Technology

To boost production efficiency while maintaining product precision, multi-hole die heads and variable frequency cutting systems are critical components of advanced PLA straw extrusion machines.

1. Multi-Hole Die Heads for Higher Output

Traditional extrusion lines produce straws one at a time, which severely limits production speed. In contrast, the multi-hole die head system—standard in Sunrise’s LG-A11 and LG-E series—allows simultaneous extrusion of multiple straws, significantly increasing output without compromising consistency.

For example:

• A 4-hole die can produce four identical straws per extrusion cycle.

• An 8-hole or even 16-hole configuration is available for high-demand facilities.

These die heads are precisely engineered to ensure uniform flow through each outlet, resulting in identical diameter and wall thickness across all straws being extruded.

2. Variable Frequency Cutting Systems

Once straws are formed and cooled, they must be cut to length. This is where variable frequency cutting (VFC) technology comes into play. Unlike fixed-speed cutters, VFC systems automatically adjust the cutting speed and frequency based on:

• Extrusion speed

• Straw length requirements

• Real-time feedback from sensors

This intelligent coordination between the extrusion and cutting systems minimizes waste, enhances dimensional accuracy, and supports rapid length changeovers—especially useful when shifting between short and long straw formats in a single production session.

Role of Automation and PLC Control in Size and Format Conversion

Automation is essential for modern manufacturing, and PLA straw making is no exception. Sunrise Machinery’s extrusion lines are equipped with PLC (Programmable Logic Controller) systems and touchscreen HMIs (Human-Machine Interfaces) that give operators full control over the production process.

1. Centralized Parameter Management

Through the PLC interface, users can:

• Adjust temperature zones, screw speeds, and cutting frequencies

• Control cooling systems, vacuum calibrators, and air compressors

• Monitor real-time output data, including straw count, length, and diameter

All these functions can be pre-programmed into the system’s memory, allowing quick recall of settings for different straw types.

2. Seamless Transition Between Products

With PLC control, operators can switch from one straw format to another with just a few screen taps. Whether changing from 6mm to 8mm straws or shifting from straight to bent formats, the machine reconfigures itself accordingly, minimizing manual intervention.

This automated reconfiguration reduces production downtime, labor costs, and operator error—while enhancing responsiveness to customer orders and market trends.

Case Study: Customizing Straw Production with Sunrise PLA Straw Machines

Let’s consider a real-world example of how a customer used Sunrise’s LG-A11-55 full-automatic PLA straw making machine to diversify their product offering.

Client Background:

A beverage company needed to produce both:

• 6mm x 200mm straight straws for iced coffee

• 12mm x 180mm spoon-tipped straws for frozen smoothies

Solution:

Using Sunrise’s LG-A11-55 system, the client:

• Installed two interchangeable die heads—one for 6mm, another for 12mm

• Programmed cutting lengths and extrusion settings into the PLC

• Attached a spoon-molding module at the cutting station for specialty straw ends

By scheduling alternating production runs, the company was able to meet both product demands without investing in two separate production lines. Downtime between product changes was reduced to less than 30 minutes thanks to tool-free mold swaps and preset automation recipes.

This case illustrates how Sunrise Machinery enables customization, flexibility, and efficiency—making it easier for manufacturers to serve niche markets without increasing operating costs.

Conclusion and Recommendation: Choosing the Right Machine for Versatile Straw Production

As the demand for biodegradable straws grows, flexibility in production has become essential. Manufacturers need machines capable of producing various straw sizes and shapes efficiently, without excessive downtime or waste. PLA straw making machines, such as the Sunrise LG-A11 Series, offer advanced features like multi-hole die heads, PLC automation, and variable frequency cutting systems—ensuring fast changeovers, high precision, and consistent output.

With the right equipment, you can diversify your product range, meet evolving market needs, and stay compliant with sustainability standards. Whether you’re upgrading your current line or starting a new PLA straw production business, Hangzhou Fuyang Sunrise Machinery Co., Ltd. provides a wide selection of machines—from economical LG-E Series models to fully automated LG-A11 systems—tailored to your specific requirements.

Explore more about their innovative PLA straw making machines and find the perfect solution for your production needs by visiting www.hzsmachinery.com. Contact Sunrise today to discuss how their expertise can help boost your manufacturing capabilities.