Search

This research concerns the development and implementation of ground-breaking strategies for improving the sorting, separation, and recycling of common flexible laminate packaging materials. Such packaging laminates incorporate different functional materials in order to achieve the desired mechanical performance and barrier properties. Common components include poly(ethylene) (PE), poly(propylene) (PP), and poly(ethylene terephthalate) (PET), as well as valuable barrier materials such as poly(vinyl alcohol) (PVOH) and aluminium (Al) foils. Although widely used for the protection and preservation of food produce, such packaging materials present significant challenges for established recycling infrastructure and, therefore, to our future ambitions for a circular economy. Experience from the field of ionic liquids (ILs) and deep eutectic solvents (DESs) has been leveraged to develop novel green solvent systems that delaminate multilayer packaging materials to facilitate the separation and recovery of high-purity commodity plastics and aluminium. This research focuses on the development of a hydrophobic DES and the application of a Design of Experiments (DoE) methodology to investigate the effects of process parameters on the delamination of PE/Al/PET laminate packaging films. Key variables including temperature, time, loading, flake size, and perforations were assessed at laboratory scale using a 1 L filter reactor vessel. The results demonstrate that efficient separation of PE, Al, and PET can be achieved with high yields for material and solvent recovery. Recovered plastic films were subsequently characterised via Fourier-transform infra-red (FTIR) spectroscopy, Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA) to qualify the quality of plastics for reuse.

Deep Eutectic Solvents (DESs) show promising abilities for the delamination of multilayer packaging films that are used in food packaging and in pharmaceutical blister packs. Due to the complexity of their structure, the recycling of such materials is a challenging task, leading to the easiest or cheapest disposal option of either landfill or incineration. Towards the development of ‘green’ solvents for efficient waste management and recycling, this research focuses on the preparation of a range of hydrophobic and hydrophilic DESs based on carboxylic acids in combination with various naturally derived aliphatic and aromatic organic compounds as well as amino acids. Chemical and physical characterization of the solvents was undertaken using differential scanning calorimetry, rheometry, and density measurements for the determination of their properties. Subsequently, batches of solvent were tested against different types of consumer packaging to evaluate the ability of the DES to delaminate these structures into their component materials. The laminate packaging waste products tested were Al/PE, PE/Al/PET, Al/PE/paper, and PVC/PE/Al. Separated films were collected and studied to further examine the effect of solvent delamination on the materials. Depending on the DES formulation, the results showed either partial or full delamination of one or more of the packaging materials, albeit there were challenges for certain solvent systems in the context of delivering a broad delamination efficiency. Variables including temperature, agitation rate, mixing time, and solvent ratios were investigated via a Design of Experiments process to assess the effects of these parameters on the delamination outcome. The results showed that the DESs presented in this research can offer an efficient, low-energy, affordable, and green option for the delamination of laminate packaging materials.

Conversion of chemical feedstocks derived from fossil fuels to virgin polymer, manufacturing of plastics in coal-dependent economies, and increasing consumption of virgin polymers for plastics packaging contribute significantly to environmental issues and the challenges we face. Nowadays, promoting sustainable development has become the consensus of more and more countries. Among them, the recycling of multilayer packaging is a huge challenge. Due to the complexity of its structure and materials, as well as the limitations of existing recycling frameworks, currently, multilayer packaging cannot be commercially recycled thus resulting in a series of circular economy challenges. It is undeniable that multilayer packaging offers many positive effects on products and consumers, so banning the use of such packaging would be unwise and unrealistic. Developing the appropriate processes to recycle multilayer packaging is the most feasible strategy. In recent years, there have been some studies devoted to the recycling process of multilayer packaging. Many of the processes being developed involve the use of solvents. Based on the recycled products, we categorised these recycling processes as solvent-based recycling, including physical dissolution and chemical depolymerisation. In physical dissolution, there are mainly two approaches named delamination and selective dissolution–precipitation. Focusing on these processes, this paper reviews the solvents developed and used in the last 20 years for the recycling of polymers from multilayer packaging waste and gives a summary of their advantages and disadvantages in terms of cost, product quality, ease of processing, and environmental impact. Based on existing research, one could conclude that solvent-based recycling methods have the potential to be commercialised and become part of a standard recycling process for polymer-based multilayer packaging. The combined use of multiple solvent-based recycling processes could be a breakthrough in achieving unified recycling of multilayer packaging with different components.