REPLACEMENT OF NON-RECYCLABLE MULTILAYER LAMINATE WITH

RECYCLABLE POLYOLIFIN BASED MATERIAL IN FLEXIBLE PACKAGING

Goyat Arohit, Verma Sushma, Sarita, Bijender

ABSTRACT

At present the most complicated issue in the world is the plastic management or we can say
that the handling of plastic is crucial due to unawareness about its pros and cons. There are
various types of plastic available which having different properties and by combined them
together their properties enhance. Here we will discuss about the replacement of non-
recyclable multilayer laminate into polyolefins based recyclable laminates. The polyolefins
are easily recyclable and can be used again and again by changing the form of packaging.
Integration, segregation and dispersing are the three most widely used recycling technologies
to achieve flexible quality reusable. Combining the addition of certain additives based on the
resin formation of the film, in part of the film during extrusion, to strengthen bonds between
various polymers.

INTRODUCTION

The use of flexible packaging is growing across every industry, the flexibility is the main
reason to consider the option. But there are even more benefits we can get from flexible
packaging films. The manufacturers of consumer goods discover the innovations by use of
flexible films in the packaging field.

Most importantly, the creation of Flexible Packaging is more ecologically benevolent than
other options, for example, metals and glass.

• It is more affordable, yet additionally offers more prominent solidness and item
assurance.

Multi-line packaging is a multilayer or composite material that uses new technologies that
aim to provide barrier properties, strength and ultimate durability for the package
performance. The material construction of any flexible packaging ranging from paper to

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plastics to metals or many others as the new technologies came in to the role. Multilayer
Flexible Packaging is a blend of at least two layers of polymer into an incorporated web that
gives defensive, utilitarian and printing properties. In addition to reducing the footprint of
carbon footprint, Multilayer Flexible Packaging has the advantage of a higher product than
the packaging rate compared to other basic packaging. In general, there are two types of
multi-pack packaging - supported and unsupported. The supported structure consists of
plastic and non-plastic layers such as paper and aluminum foil, while the unsupported
structure consists only of plastic layers with interlocking barriers.

Currently, there are no mandatory Multilayer Flexible Packaging standards available so the
structure can vary from two layers to up to 9 layers.

RECYCLING OF MULTILAYER LAMINATES

Integration, segregation and dispersing are the three most widely used recycling technologies
to achieve flexible quality reusable. Combining the addition of certain additives based on the
resin formation of the film, in part of the film during extrusion, to strengthen bonds between
various polymers.

In the process of delamination, the various layers of Multilayer Flexible Packaging are
separated by the removal of attachments using a specific solvent. The selected finish is
another method used to melt and reduce the various layers of Multilayer Flexible Packaging.
After disintegration, the polymer was separated using a quantitative variation.

The presence of ink on the face of Multilayer Flexible Packaging is one of the biggest
obstacles to effective reuse. De-inking processes such as degassing and the use of chemicals
to remove ink make the final product release its physical properties which means that the
strength of the polymer chemical bond is reduced.

Multilayer Flexible Packaging is used to make substandard products such as garbage bags,
pipes, bags, lumbar etc. in the current technology of Multilayer Flexible Packaging recycling
technology. Reuse of Multilayer Flexible Packaging is currently being done on a small scale
due to many factors such as food contact rules and restrictions on recycled plastic packaging.

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REVIEW LITERATURE

RECYCLING OF POLYMER- BASED MULTILAYER PACKAGING [1]-Plastic-based

multilayer composite materials are ordinarily utilized to consolidate the separate presentation
of various polymers. By this methodology, the custom fitted usefulness of bundling ideas is
made to adequately secure delicate food things and then we find an extended period of
usefulness. In any case, due to the recurring inefficiency, most of the composite materials are
generally burned, destroying the efforts possible towards the green economy. At present the
postconsumer waste becomes the big problem for every country. Their environment team
regularly working on the best possible ways to minimize the use of multilayer or finding the
way to handle this waste. The possibility of reusing of the multilayer divided in to two phases
in which one produces strategies for achieving the division of the various phases, either by
delamination or by a specific strategy for the separation of the divisions, while collaborative
strategies and methods of dispersion reduction are now widely considered, bundling
termination has not been fully researched.

ACTIVE PACKAGING BY EXTRUSION PROCESSING OF RECYCLABLE AND

BIODEGRADABLE POLYMERS [2]-In this work is presented the first study of the
suitability of active non-environmental films that will be performed through the extrusion
process. The results suggest that temperature monitoring plays a key role in determining the
antimicrobial efficacy of the active films under investigation. In particular, antimicrobials
included in PLA and LDPE showed low antimicrobial activity retention, thus losing some
function due to high processing temperatures. On the other hand, PCL was processed at low
temperatures, which allowed for a slight reduction in anti-microbial activity.

PROPERTIES OF WHEY PROTEIN COATED FILMS AND LAMINATES AS

RECYCLABLE FOOD PACKAGING MATERIALS WITH EXCELLENT BARRIER
PROPERTIES [3]-In the packaging of food material the oxygen and water are the two major
parameters which plays an important role to save the product from environment and protect
its life At present the available raw material i.e polymers are used in combination to give the
required barriers. For example to pack the crispy material the layer of plastic and aluminum,
improve the shelf life of the packed product. There properties combined and protect the
product from deteriorating. Today’s research efforts are focused on advancing functions of
material maintaining the practical properties of future binding materials. The single material
properties are limited but when it is combined the critical properties overcomes. To give
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additional properties, some material is used as a coating which add its properties in the
material and makes the material multilayer. The EVOH and PVDC are the two material
which is widely used as a coating material to enhance the package properties so that it can
sustain the product in its defined life cycle. To improve the OTR and WVTR different types
of material combined with the help of adhesive or plastic material as an extrusion process.

RECYCLABILITY BY STRUCTURE FOR MULTILAYER FLEXIBLE PACKAGING [4]- At

customers end, a sense of obligation towards plastic packaging waste isolation was noticed,
anyway an absence of comprehension about recyclable multilayer plastic flexible packaging
was likewise uncovered through buyer study. This factor been distinguished as an advertising
opportunity. Greater part partners have an attraction towards single use plastic for recyclable
plan. It offers a knowledge for the eventual fate of multilayer plastic flexible packaging, its
plan and recyclability in world organisation. In any case, hindrance related issues are
apparent with mono-material multilayer plastic flexible packaging that ought to be
contemplated. Mono-material based multilayer plastic flexible packaging is presently more
cost serious than regular multilayer plastic flexible packaging.

RECYCLING ASSESSMENT OF MULTILAYER FLEXIBLE PACKAGING FILMS

USING DESIGN OF EXPERIMENTS [5]- Initially, small particles of PET-PE were
extracted from new polymers and mixed with various details, according to the test (DOE)
system. Polymer compibilizers supported by maleic anhydride (PE-g-MA) and glycidyl
methacrylate (E-GMA) tend to increase the compliance response. The physico-mechanical
properties of the model compounds were tested with an over-the-counter (RSM) response.
Finally, the rear of the machine was incorporated into the same combination of components
within the previous modeling models.

PE-BASED MULTILAYER FILM STRUCTURES [6]- Flexible packaging is utilized to

secure the item during transportation and circulation, give data and, in the retail climate, pull
in the buyer to the item. Various layers are frequently used to give usefulness at least
cost. Co-extrusion has advanced into a practical cycle for producing multilayer films,
with polyethylene and its copolymers used in the best volume. In the wake of auditing key
parts of polymer choice for mechanical, boundary, fixing and grip execution, the utilitarian
prerequisites of explicit adaptable bundling applications and typical multilayer

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structures used to meet them are talked about. Applications incorporate clinical, food and
modern bundling.

RECYLABILITY AND MECHANICAL PROPERTIES - MATERIALS RECYCLED

FROM MULTILAYER FLEXIBLE PACKAGING [7]- Recycling type for multilayer flexible
food packaging to avoid incineration, waste disposal or reuse of parts. The manufacturing
process consists of bonding multiple sheets with different simultaneous use of heat and
pressure, these are bonded with polyethylene bonding, without the other adhesives. A three-
point bending test was performed, with the aim of finding the flexural and modulus flexus
strength. Finally, reliability is determined by the Weibull method using a failure rating that
differs from the most relevant factors.

RE-PROCESSING OF MULTILAYER PLASTIC MATERIALS [8]- This experiment aims

to test properties of multilayer laminate after reusing and helps in increasing the social
awareness of plastic material selection. The selection on material became the main reason of
its performance as per product requirements. The reused plastic material being tested and
checked for its mechanical properties. Depending on the results of chemical and mechanical
properties, material used for food or any other type of packaging on the basis of its
brightness, softening and material elongation. The different type of plastics has variety of
display the visual structures.

MULTILAYER PACKAGING- ADVANCEMENT IN PREPARATION TECHNIQUES AND

EMERGING FOOD APPLICATIONS [9]- This work provides an in-depth survey of
headways in multilayer film editing applications for food integration. This takes into account
the basic assumptions of suspension, the risk of collusion between the bulk and the food, the
display of prices and entertainment, the potential for escalation, and the costs involved. The
effect of package management - similarly clarified by considering the conditions of warm
unpreparedness and warm-up development. Significantly, the challenges associated with the
demolition and reuse of multilayer piles and related storage methods have been explored.

SUSTAINABLE APPROACH TO RECYCLING OF MULTILAYER FLEXIBLE PACKAGING

USING SWITCHABLE HYDROPHILICITY SOLVENTS [10]- Multilayer Flexible Packaging
Waste represents the largest component of packaging waste and is composed mostly of multi-
layered plastic films laminated with Al foil. In the European countries, chemical and
chemical recycling technologies are often used to separate polymeric particles. However,
these recycling practices have some limitations related to the rate of recycling, energy
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consumption, CO2 emissions, sustainability, and the unavailability of the obtained polymer
blends, which contradicts the objectives of the economic strategy. The current research aims
to improve the chemical and ultrasonic treatment of recycling multilayer flexible packaging
waste while overcoming the above-mentioned limitations. Finally, emissions equivalent to
CO2 and the economic performance of advanced technologies were tested.

SUSTAINABILITY OF FLEXIBLE MULTILAYER PACKAGING: ENVIRONMENTAL

IMPACTS AND RECYCLABILITY OF PACKAGING FOR BACON IN BLOCK [11]-
Multilayer plastic packaging is difficult to recycle and is considered an environmental
problem, despite its valuable protective properties. This study looks at the environmental
impacts and regeneration of six independent packaging blocked the packaging solutions. In
addition, it takes into account the natural effects of the combined product. Variable tested
packaging includes thermoformed films (polyamide (PA) / polyethylene (PE) and PE /
ethylene vinyl alcohol (EVOH)). A Life Cycle Assessment birth test was performed. The
environmental impacts are highly dependent on the packaging. The average carbon footprint
of carbon combined is 54 times more than the carbon footprint. Given the low environmental
value of packaging compared to packaged product, complete product protection should be a
priority for packaging designers.

RESEARCH OBJECTIVE

The objective of the project is to get an alternate of multilayer (non-recyclable) flexible

packaging using different suitable materials at “Aero Plast Ltd., MIE Metro Station,
Bahadurgarh, Haryana”.

Ø To provide recyclable polyolefin derivatives as an alternate of non-recyclable

multilayer Laminate in context of flexible packaging.

METHODOLOGY

1. Study of Existing non-recyclable or multilayer laminate which is presently used in the

packaging/printing industry (i.e. 12µ PET/60µ N Poly)

2. Study of best possible alternate options of multilayer flexible packaging in Industry.

During project work will collect samples of both (Existing and proposed structures)

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 for data analysis from the company “Aero Plast Ltd., MIE Metro Station,
Bahadurgarh, Haryana”.

3. Evaluation of Existing structure samples will be done.

4. Testing of all parameters will be done for the existing structure- 12µ PET
(polyester)/60µ N Poly(polyethylene).

5. A comparison chart will be prepared on all necessary parameters of its performance.

6. The proposed Alternate material (18µ BOPP/60µ N Poly) will be manufactured at

“Aero Plast Ltd., MIE Metro Station, Bahadurgarh, Haryana”.

7. All parameters will be tested for new purposed alternate material (18µ PET/60µ N
Poly) and also graph will be made on the basis of test results.

8. A comparison data shown for all parameters of performance old material (12µ
PET/60µ N Poly) and alternate proposed material (18µ BOPP/60µ N Poly) and also
shown a cost comparison done on the basis of current raw material prices.

9. A cost comparison done on the basis of current raw material prices and cost chart will
be prepared to check the impact of the same in the industry.

10. Testing of recyclability will be done from CIPET: SARP- Laboratory For Advanced
Research In Polymeric Materials (LARPM) to verify the results.

CONCLUSION

Conclusion of this research is that we will get the recyclable structures whose applications are
wide specially in the food packaging industry. This will also help to make the flexible plastic
packaging handling process easy and convenient for reuse and recycling.

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