The Importance of Multilayer Co-Extruded Film in Biopharmaceutical Manufacturing

What Is Co-Extruded Film?

Co-extrusion is a manufacturing process where multiple layers of different polymers are combined during extrusion to form a single, uniform multilayer plastic film. Unlike laminated films, co-extruded films offer seamless integration between layers, reducing the risk of delamination or contamination. Achilles offers 1 to 5 layer structures, using up to four different polymers, including PE, PP, EVOH, EVA, COPE, and Nylon, materials widely used in bioprocessing film applications.

Built for Cleanroom Performance

Our co-extruded films are produced in a custom-built ISO Class 7 cleanroom, ensuring contamination-free manufacturing from start to finish. Features include:

• In-line optical defect inspection

• Automated thickness monitoring

• Custom resin selection and formulation support

  
  

This level of precision and control is essential for maintaining biocompatibility, sterility, and functional reliability in single-use systems.

Why Use Multilayer Co-Extruded Film for Bioprocessing?

1. Superior Purity & Consistency

Every layer is produced in a controlled environment, minimizing extractables and leachables. This ensures that the integrity of the bioprocessing materials is maintained throughout their lifecycle.

2. Custom Barrier Properties

Incorporate materials like EVOH for gas barrier protection, which is essential for sterile packaging and fluid containment. This customization allows for tailored solutions that meet specific process requirements.

3. Mechanical Strength & Flexibility

Tailor tensile strength and flexibility to support bag welding, sealing, and flow control in bioprocessing equipment. This adaptability is crucial for optimizing performance in various applications.

4. Scalability & Compliance

Our films are developed with long-term production and regulatory alignment in mind, making them ideal for scaling from pilot to commercial production. This scalability ensures that your bioprocessing operations can grow without compromising quality.

Applications in Bioprocessing

Achilles' Multilayer Co-Extruded films for bioprocessing are used in:

• Single-use bioreactor bags

• Media and buffer storage systems

• Sampling and transfer bags

• Sterile filtration and diagnostic devices

  
  

Each application benefits from our ability to engineer film properties based on your process requirements. This versatility allows for a wide range of uses in the biopharmaceutical industry.

Global Production and Support

With facilities in the USA and Japan, Achilles offers secure, dual-sourced production and a flexible supply chain to support our global partners. Our collaborative approach allows clients to co-develop custom film structures, ensuring that performance, compliance, and production timelines align from concept to delivery.

Partner With Achilles for Bioprocessing Film Innovation

From raw material selection to final roll testing, Achilles provides full-service custom film manufacturing for bioprocessing applications. Whether you're developing a new single-use system or improving an existing one, we’re here to deliver co-extruded film solutions that support the future of healthcare.

Contact us to learn how our multilayer films can support your bioprocessing innovation.

The Future of Biopharmaceutical Manufacturing

As the biopharmaceutical industry continues to grow, the demand for innovative materials will increase. Multilayer co-extruded films are at the forefront of this evolution. They provide the necessary properties for safe and effective bioprocessing.

Innovation in Material Science

The development of new polymers and co-extrusion techniques will enhance the capabilities of multilayer films. This innovation will lead to improved performance and reliability in biopharmaceutical applications.

Sustainability Considerations

As environmental concerns rise, the biopharmaceutical industry must also focus on sustainability. Multilayer films can be designed with eco-friendly materials, contributing to a more sustainable future.

Regulatory Challenges

Navigating the regulatory landscape is crucial for biopharmaceutical manufacturers. Our films are designed with compliance in mind, ensuring that they meet all necessary standards.

Conclusion

In conclusion, multilayer co-extruded films are essential for the future of biopharmaceutical manufacturing. Their unique properties and adaptability make them ideal for a variety of applications. Partnering with Achilles ensures that you have the best materials for your bioprocessing needs.

Contact us today to explore how we can assist you in achieving your biopharmaceutical goals.