Labtech Engineering introduces a GMP-compliant laboratory cast film and sheet extrusion line developed specifically for high-grade medical and pharmaceutical polymers, including advanced materials such as polycaprolactone (PCL).
The system is engineered for gentle melt handling and highly controlled thermal regulation from extrusion through to film winding, ensuring a stable and repeatable production process. The extrusion line consistently produces defect-free films with uniform thickness, smooth surface finish, and excellent optical clarity, meeting stringent medical application requirements.
Single-screw extruder (LEM25-30/C)
The low-shear extrusion design preserves molecular structure while minimizing gel formation, haze, and thermal degradation of sensitive medical polymers. The extruder barrel features three independently controlled heating zones; feeding, melting, and metering, each equipped with electric heating and precision cooling channels for fast and accurate temperature response.
Film thickness and surface quality are controlled using a precision flat die combined with a two-roll chill-roll stack, ensuring smooth film transfer and uniform cooling.
The flat die is positioned close to the first chill roll to minimize neck-in and maintain consistent film width across the entire production run. The two-roll chill-roll system features independent temperature control over a wide operating range, allowing both rapid quenching and controlled crystallization depending on material requirements. The downstream section is designed for hygienic film handling and precise finishing, ensuring film quality is maintained throughout the entire process.
Stainless-steel guide rolls provide accurate film alignment and easy cleaning, while the edge trimming unit delivers clean, precise film edges. Adjustable pull rolls allow fine control of line speed and film thickness, supporting stable operation during extended production runs. Silicone rubber wind-up rollers ensure gentle film contact during winding, protecting delicate films from surface damage. A cassette collection system enables safe, hygienic handling and convenient storage of finished film rolls.
Case Study: Processing of PLC
Material Target
A premium-grade biodegradable polymer was used in this project, intended for advanced medical and pharmaceutical research applications. The material was supplied in virgin form without prior thermal processing, designed for high-purity film production in laboratory and pilot-scale environments.
Processing Challenges
The polymer featured a broad molecular-weight distribution, making it difficult to process consistently. Without precise temperature regulation, the melt easily develops gels and surface defects, resulting in poor film clarity. The goal is to achieve stable, defect-free film extrusion through highly accurate thermal and cooling control under GMP conditions.
Outcome
Using the Labtech Cast Film and Sheet Extrusion Line Type LCRM/2/145-300, the process successfully delivered uniform, gel-free films with consistent thickness and clear surface appearance. The results confirmed the line’s capability to handle sensitive medical-grade polymers with outstanding process stability, repeatability, and clarity, validating its suitability for research and development and drug-delivery applications.