What Is Co-extruded Film?

In the world of flexible packaging and industrial applications, innovation continues to redefine the way materials are manufactured, offering solutions that not only enhance performance but also unlock new possibilities; amongst these is co-extruded film, a versatile, multi-layered material that has become a staple across various industries. However, what is co-extruded film, how does the process occur, and what are the benefits of it?

Understanding the Co-Extrusion Process; Crafting Complexity

The co-extrusion process is highly technical and requires specialised equipment. Manufacturers can control the thickness and properties of each layer to achieve the desired characteristics in the final film. This process is not your conventional monolayer plastic sheet; it is a product of advanced extrusion technology that involves simultaneously extruding multiple layers of distinct polymers to create a single, cohesive film. Each layer contributes unique characteristics, such as strength, flexibility, barrier properties, or enhanced aesthetics, all of which provide a set of benefits to a business that uses this technology. Therefore, it is no surprise that various industries, such as retail packaging and agriculture, use this film.

Knowing the Characteristics; Multiple Layers Full of Benefits

The complex process of co-extrusion creates a range of characteristics, each of which provides advantages for the users of this film; this is why businesses are eager to involve the use of co-extruded film wherever it is suitable and possible. That being said, what are these characteristics and benefits of co-extruded film?

Enhancing Properties

As mentioned in the co-extrusion process section, this type of film has multiple layers of polymers, and the combination of these layers provides enhanced properties compared to a single-layer film. Each layer’s distinct properties may provide a benefit such as optical clarity, strength, or flexibility.

Versatility

Co-extruded films are manufactured to be versatile and can be customised to meet specific requirements for various applications. The number and type of layers can be adjusted based on the desired properties of the final film.

Barrier Properties

Co-extruded films are frequently used in applications where barrier properties are crucial, such as in food packaging. The film can extend the shelf life of packaged products, as the multiple layers can be designed to provide protection against light, oxygen, moisture, and other external factors.

Cost Efficiency

The co-extrusion process allows manufacturers to use different materials only where they are necessary, optimising the use of more expensive materials; this can result in cost savings compared to using a single material for the entire film, where unnecessary raw materials are often wasted.

Specialised Applications

Co-extruded films can be used in various industries, as they’re designed to fit their intended purpose. The specific combination of layers and the resulting properties chosen depends on the intended use of the film, creating enhancements for purposes such as medical packaging, food packaging, construction, and more.

Printing and Labelling

Co-extruded films are often useful for packaging that requires labelling, as they can be designed to facilitate printing and labelling processes. If the layers are optimised for adhesion and printability, the product information and branding can easily be applied directly to the packaging.

Recyclability

Recyclability is an important topic within the manufacturing industry, and fortunately, co-extruded film can be designed with this in mind, depending on the materials used. As many businesses turn towards sustainable solutions to packaging, the use of co-extruded film could be particularly beneficial and impactful for manufacturing ethics towards protecting the environment.

Co-Extruded Films vs Monolayered Films

Both co-extruded films and monolayered films offer benefits to businesses; however, they are distinctly different in their properties and uses. The choice between these films depends on the specific requirements of the intended application.

Co-extruded films shine in situations where a combination of properties is essential, allowing for greater customisation, but monolayered films are limited in this aspect. Co-extruded films are therefore used for a wider range of packaging compared to monolayered films, which tend to only suit basic packaging needs, due to their limited barrier properties and reduced versatility. However, since the co-extrusion process is complex, it is often a more expensive option compared to the monolayer process.

Co-Extruded Films vs Laminated Films

Co-extruded films and laminated films are both multi-layered materials, but they differ in terms of their manufacturing processes and certain characteristics. Co-extruded film is produced through a simultaneous extrusion process where multiple layers of different polymers are extruded at the same time, creating a single, integrated film. In comparison, laminated films are created by bonding together multiple pre-produced layers using adhesives, heat, pressure, or a combination of these methods, and the layers are typically distinct and produced separately before being combined.

Laminated films can be customised by selecting and combining pre-produced layers. However, the control over these layers is limited compared to co-extrusion; this means they are less versatile, integrated barrier performance is reduced, and bonds could be weaker. Similarly to monolayered films, laminated films cost less to produce compared to co-extruded films, because layers can be produced independently before lamination.

Industry Highlight; IPP and LLDPE-Manufactured Stretch Film

There are many types of co-extruded films available in the manufacturing market, all of which bring different purposes and benefits; we’ve chosen two frequently used types to discuss, which are IP Performance film (IPP), a bio-based material made from sugarcane, and Stretch film, which is manufactured using Linear Low-Density Polyethylene (LLDPE). We supply both these types of film, so if they sound suitable for your business, get in touch for more information.

IPP film is a lightweight, high-performance co-extruded film, which offers significant levels of strength whilst offering substantial cost savings against monolayered films. This film is engineered from a unique blend of polymer, with additives to make the film very high strength and as a multi-layered film, it has been optimised to be tear-resistant and durable. IPP is also a lightweight, sustainable film since the amount of material involved has been reduced; this helps our customers meet their sustainability goals.

Stretch film, manufactured using LLDPE, is typically used for pallet-wrapping, bundling, and securing, protecting products and pallets from item loss and damage. Stretch film is made using two main methods; blown and cast. Both these films have high tear and puncture resistance and protect against moisture, gases, and aromas. Cast stretch, produced using a cast extrusion process, is very clear and glossy in appearance and has moderate durability and consistent cling. Blown stretch film, made using a blown extrusion process, is hazy and dull in appearance and has very high durability and a high level of cling.

Both types of stretch wrap have different advantages, depending on their designated usage. Blown stretch film is the best option for wrapping sharper-edged objects and heavier loads due to its greater durability, whilst cast stretch film is used for lighter products and loads stacked on pallets. Since cast stretch film is clearer, it is ideal for scanning barcodes and seeing labels through the film; in fact, cast stretch film is now used by 70-80% of the industry globally, so it is the more commonly used option.

Are You in Need of High-Quality, Co-Extruded Film?

Looking for stretch film/wrap for your organisation? Get in touch with Industrial Polythene at https://www.ipoly.uk.com/contact-us to discuss your requirements and our friendly expert team will help find the perfect solution for you.