This case study addresses a major challenge in the circular economy: the recyclability of multilayer plastic packaging. The project developed an innovative MultiNanoLayered (MNL) film designed to be fully recyclable while maintaining the high performance required for food packaging.
Challenges
The reference product is a conventional multilayer film used for food packaging (e.g., for cheese or meat). These films are notoriously difficult to recycle for several reasons:
- Complex Material Composition: They are typically made of several different, incompatible polymer layers (e.g., Polyolefin, PA, EVOH, compatibilizer) that cannot be easily separated in standard recycling streams.
- Poor End-of-Life Outcome: Due to these issues, the vast majority of multilayer films are not recycled and are instead sent to landfill or incinerated, representing a significant loss of valuable resources.
- NIAS Contamination: The presence of Non-Intentionally Added Substances (NIAS), which can be degradation products or contaminants, is a concern for food contact materials and their potential for recycling back into food-grade applications.
Objectives
The objective was to design a high-performance multilayer film that is fully compatible with existing recycling streams. The specific KPIs were:
- Performance: Achieve an Oxygen Transmission Rate (OTR) of < 10 (ml)/(m².day), which is comparable to or better than most conventional films.
- Safety: Optimize the use of compatibilizer. The aim is to improve upon this percentage, making the films more efficient. Additionally, the objective is to reduce the release of NIAS (non-intentionally added substances) by more than 10% during realistic life cycle simulations.
- Sustainability: Achieve a 60% reduction in C-Footprint versus current solutions.
- Recyclability: Prove the recyclability of MNL films, by applying the Recyclass technology approval methodology, and achieving the benchmark recommendations, including the preservation of mechanical properties above 75% compared to control.
- Cost: Ensure no cost increase versus state-of-the-art multilayer films.
Our SSRbD Approach & Key Findings
The SURPASS solution is an innovative MultiNanoLayered (MNL) film made from a simplified combination of polyethylene (PE) with ethylene vinyl alcohol (EVOH) or polyethylene (PE) with polyamide (PA). This design-for-recycling approach allow to optimize the use of compatibilizer.
- Environmental Performance (LCA): The LCA results showed a clear environmental benefit for the innovative film. The primary hotspot for both the reference and innovative films is raw material production. SSRbD film shows a significantly improved environmental profile across most impact categories.
- Economic Viability (LCC): The LCC analysis demonstrated that the innovative SSRbD film has a potentially lower total cost than the conventional reference. This advantage is driven by three factors: the use of recycled raw materials, and the financial benefits from eco-modulation taxes that penalise non-recyclable packaging.
- Hazard & Release Assessment:
- Hazard: Migration tests were conducted on the innovative films and demonstrate a low migration level with no toxicological effect in the in vitro assays.
- Release: The release of microplastics during simulated consumer use was similar and very low for both the reference film and the MNL film. For specific migration into food simulants, the SSRbD solutions showed lower release of inorganic NIAS but higher release of organic NIAS compared to the reference due to the lack of adhesion between the layers of the MNL film
Key Takeaways
This case study is a powerful example of "design for recycling". By simplifying the material composition and eliminating problematic substances from the outset, it is possible to create a high-performance product that is both environmentally superior and economically advantageous. It underscores that smart design choices at the beginning of the lifecycle are the most effective way to enable a circular economy for plastics.