Abstract: With the wide application of low-smoke halogen-free material, low extrusion speed and high extrusion load have troubled enterprises. In the paper, a high-efficient extrusion screw featuring constant pitch with varying channel depth and low compression ratio was designed to reduce extrusion pressure while increasing extrusion output. Die configuration was designed and optimized to reduce extrusion draw-down ratio, effectively addressing the issue of excessive head pressure during the extrusion of low-smoke halogen-free materials. Temperature of extruder was set scientifically to reduce high extrusion pressure with unstable throughput during low-smoke halogen-free material extrusion caused by high screw shear forces and friction temperature rise. Ratio of extruder transmission wheel was adjusted to increase torque. Results showed that the aforementioned measures could effectively reduce the main motor load while increasing the extrusion speed of low-smoke halogen-free materials.