Elodie Bugnicourt Lorena Rodríguez · Lorena Rodríguez Recycling of complex packaging materials Breakout group 1 5 May. BIO -BA SED RECYCL ABLE P ACKAGING Plastics are everywhere

BIO -BA SED RECYCL ABLE PACKAGING

E l o d i e B u g n i c o u r t

L o r e n a Ro d r í g u e z

Recyc l ing of complex

packaging mater ia l s

B r e a k o u t g r o u p 1

5 M a y


P l a s t i c s a r e e ve r y w h e r e

Total demand in EU:51.2 Mt

Source: PlasticsEurope, Plastics, the facts 2019

R e a l l y e v e r y w h e r e !


• Banning of SUP -> alternative materials needed (excluded packaging)

• All plastic packaging on the EU market recyclable by 2030 (and recycling thereof reaching 55%)

• Make recycling profitable for business

• Drive investment & innovation


H ow d o we s t a n d ?

t ex t

+

42% in case of packaging

source: Plastics Europe


L i n e a r f l ow w i t h h u ge l e a k s

picture: Ellen Mc Arthur fundation


M o n o - m a t e r i a l s r e c yc l i n g

Source: IFP Energies Nouvelles, ex. for PET


M u l t i - M a t e r i a l s r e c yc l i n g :

a c h a l l e n ge i n e a c h s t e p

Source: Kaiser, K.; Schmid, M.; Schlummer, M. Recycling of Polymer-Based Multilayer Packaging: A Review. Recycling 2018, 3, 1. - Amcor- Multicyle

Plastic packaging Flexible rigid

Overall market (wt%) 43% 57%

Monolayer 86% 88%

Multilayer 14% 12%







Approximately the 70% of flexible

packaging is made up of multilayer

structures.






a c h a l l e n ge i n e a c h s t e pThe GVM (Association of Packaging Market Research) divides multilayer packaging films into five categories, polymer content higher than 50%, and packaging without paper are considered:

Source: Kaiser, K.; Schmid, M.; Schlummer, M. Recycling of Polymer-Based Multilayer Packaging: A Review. Recycling 2018, 3, 1.

These five categories made up 17.7 billion m2 , approximately 1.89 Mt.

The sum of the five most important material combinations makes up 56.3 % m2 of plastic-based flexible packaging.




Source: Kaiser, K.; Schmid, M.; Schlummer, M. Recycling of Polymer-Based Multilayer Packaging: A Review. Recycling 2018, 3, 1.

Sorting• Standard techniques won’t work

Separation and recycling• Pure fractions needed for reprocessing

• No industrially established process yet


S o l u t i o n s f o r f o o d p a c k a g i n g

m u l t i l aye r va l o r i z a t i o n :High quality methylal from non-recyclable plastic waste by an improved Catalytic

Hydro-Gasification Plasma(CHGP) process.


S o l u t i o n s f o r f o o d p a c k a g i n g

m u l t i l aye r va l o r i z a t i o n :High quality methylal from non-recyclable plastic waste by an improved Catalytic

Hydro-Gasification Plasma(CHGP) process.

• Reduction of around 3.6 tonnes plastic waste sent to landfill (accounting for 0.28 tonnes CO2 eq. or more than 304 MJ eq. per pilot plant) during the project period;

• Production of 2.88 tonnes methylal through waste resources (thus saving virgin fossil resources), leading to a reduction of 2.07 tonnes CO2 eq., more than 107 300 MJ eq. per pilot plant;

• Implementation of a cleaning process for plastic recovery;• Improved economic and environmental efficiency of the

recycling companies in order to achieve EU zero waste targets (thereby improving competitiveness);

• Job creation and a replicable strategy for recovery of plastic waste in other EU countries


S o l u t i o n s f o r r e c yc l i n g

m u l t i l aye r f i l m s b a s e d o n PARecycling methodologies for obtaining PA from food packaging multilayer films.

• Circular Recycling chain for PA food packaging multilayerfilms: Raw material supplier, compounders, packagingconverters and recyclers. To implement at a industrial scale the Recycling process developed at RECIPAM.

• Validate RPA in high value application as food packagingand automotive pieces to obtain a more sostainableproducts.

• RECIPAM technology• Delaminating process for PA multilayer separation. • Compatibilization process for PA reprocessing with

other food packaging multilayer materials, to obtaina mix of recycling plastics (PA with PE o PP) to replacepartially virgin PA.



m u l t i l aye r f i l m s b a s e d o n

P VO HRecycling methodologies high barrier packaging

New approaches

Oxygen barrier material: Tailored

made PVOH for multilayer

applications.

Sheet extrusion, blow film

extrusion, injection and

printing an lamination

NEMURE



m u l t i l aye r f i l m s b a s e d o n

P VO HRecycling methodologies high barrier packaging

Recycled packaging based on PVOH.NEMURE Technology:

• Ecodesing• Delaminating process for PVOH

multilayer separation.• Recovery of high quality PO.

NEMURE


W h ey l aye r s o l u t i o n f o r

d e l a m i n a t i n g m u l t i l aye r f i l m s

• Whey protein-coated plastic films can replace synthetic barrier polymers and increase

packaging recyclability as a new application to valorise food wastes (converting 40% of the

non valorised whey excess could cover the global need in EVOH for food packaging)

• Laminates were validated for packing pasta, cheese, sausages and converted into tubes

tested for cosmetics and thermoformed packaging (eg. blisters tested for pharmaceuticals)

Barrier biopolymers for sustainable packagingSo

urc

e: C

AD

ISo

urc

e: M

LAN

G

Sou

rce:

IRIS


• A process based on Wheylayer enzymatic removal was developed to

allow separating and recycling multilayer films

– Coating detectable by IR

– Minor loss of properties upon reprocessing

• Films are compostable when using biodegradable substrates

• LCA estimated 30% lower environmental impact than synthetic

counterparts

W h ey l aye r s o l u t i o n f o r

d e l a m i n a t i n g m u l t i l aye r f i l m s

Upscaling of material recycling and development of home compostable solutions in:

Source: E. Bugnicourt et al. (2013). Processing and validation of whey-protein-coated films and laminates at semi-industrial scale. Adv Mater Sci Eng, 2013


M u l t i c y c l e r e c yc l i n g s o l u t i o n f o r

p l a s t i c - b a s e d m u l t i - m a t e r i a l s

Sou

rce:

IRIS

We are upscaling a recycling pilot plant based on CreaSolv®

patent (preferential solvent-based extraction of specific polymer

fractions in subsequent stages) :

• Optimising each recycling and reprocessing step in an

industrial environment

• Integrating advanced monitoring and PAT solutions and

sc-CO2 upgrading among others

Source: Loemi


M u l t i c y c l e va l u e p ro p o s a l

• Tolerance to compositional variation

• Recovery of main polymers and fibres

fractions, minimised non-valorised residue

• Demonstrating recovered materials’

potential for packaging and automotive

(composites/textiles) applications

• Eco-designed secondary raw materials

applications with reduced footprint and

minimal downgrading to allow virtually

infinite multicycling

• Decision support systems for process

optimisation and secondary use

Sources: IRIS, Fraunhofer

Polymer Predicted (%)

PP 6.9

PE 29.2

PET 30.1

PA 19.9

PLA 13.7

Paper 0.1


C i r c u l a r i t y o f m u l t i l aye r

p a c k a g i n g va l u e c h a i n➢ Many complementary technical approaches (pyrolysis, solvent extraction, delamination,

organic recycling, etc.) to turn a challenge into an opportunity by making feasible and

valuable to recover secondary raw materials from multilayer packaging

picture: Ellen Mc Arthur fundation


T h a n k yo u f o r yo u r a t t e n t i o n

Elodie [email protected]

Lorena Rodrí[email protected]

Acknowledgment to EC funding for

the projects:

Ecomethylal -LIFE15 ENV/ES/000208

MultiCycle GA 820695

Wheylayer GA 315743 & 218340

Biontop GA 837761

mailto:[email protected]

mailto:[email protected]

Documents

Elodie Bugnicourt Lorena Rodríguez · Lorena Rodríguez Recycling of complex packaging materials Breakout group 1 5 May. BIO -BA SED RECYCL ABLE P ACKAGING Plastics are everywhere