The present disclosure is directed to a process for producing thermoplastic polyolefin roofing membrane. The process includes directly adding components of a high-load flame retardant TPO formulation to a counter-rotating twin screw extruder. The process includes extruding the formulation with counter-rotation of the twin screws and forming a TPO roofing membrane having a tensile strength of greater than 10 MPa and a flame retardance of rating of classification D as measured in accordance with EN ISO 11925-2, surface exposure test.