Advancing Circularity in Multilayer Film Recycling: Balancing Quality and Sustainability

Recycling multilayer films (MLFs) presents significant challenges to achieving circularity. Mechanical recycling, solvolysis (chemical recycling), and dissolution (physical recycling) have been introduced in the past with their strengths and weaknesses. This study uses a series of advanced, pilot-scale processes to improve the quality of recyclates. These include Near Infrared/Digital Watermarking (NIR/DW), super-critical CO2 decontamination, dissolution, and innovative mechanical recycling techniques (METEOR and multi-nano layering, MNL). Findings from TRL 5–8 pilots show that recycling different MLF compositions with two routes (dissolution-based and METEOR/MNL-based) can improve the overall quality but this comes with a trade-off. Using 10% recycled content from PET/PE and metalized PP films in 2050 could even increase greenhouse gas (GHG) emissions by 21% and 85%, respectively, compared to landfill incineration. However, PE/PA and PE/EVOH films showed GHG reductions of 0.5% and 4%, respectively. Raising recycled content from 0% to 50% can cut GHG emissions by 36%. These results challenge the current 10% recycled content target, advocating for a more ambitious goal of exceeding 25% by 2050 to enhance sustainability.