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Resources, Conservation & Recycling 176 (2022) 105905

Contents lists available at ScienceDirect

Resources, Conservation & Recycling

journal homepage: [Link]/locate/resconrec

Full length article

Recycling of multi-material multilayer plastic packaging: Current trends

and future scenarios
¨

Camila T'avora de Mello Soares a,* Monica Ek ,

a
, Emma Ostmark b
, Mikael Gallstedt ¨ b ,
a
Sigbritt Karlsson
a
Department of Fiber and Polymer Technology, Biotechnology and Health, KTH Royal Institute of Technology School of Engineering Sciences in Chemistry, Teknikringen
56-58, Stockholm SE-100 44, Sweden b
Stora Enso Innovation Center for biomaterials, PO Box 4158, Nacka SE-131 04, Sweden

ARTICLE INFO ABSTRACT

Keywords: Multi-material multilayer plastic packaging (MMPP) is widely applied in fast moving consumer goods (FMCG)
Multi-material multilayer packaging combining functionalities of distinct materials. These packaging structures can enhance properties, such as
Plastic packaging recycling
resource-use efficiency and barrier performance leading to consequential benefits like a prolonged shelf-life.
Advanced recycling technologies
Nevertheless, they represent a challenge for existing recycling systems, confronting circular economy princi ples.
Future foresight
Scenario planning
This study aim was to foresight the future of recycling technologies for MMPP in the next five to ten years.
Future scenarios were identified, including (1) high-performance material recycling, (2) recycling into hydro
carbons, (3) business as usual, and (4) downcycling. In-depth interviews and a feedback survey were methods
used to validate the scenario matrix while defining experts’ expectations towards the future. The analysis showed
that distinct technologies will develop unevenly in different parts of the world. A mix of all scenarios is probable in
the upcoming years, depending, essentially, on regulations and technology availability. Advanced high performance
material recycling encounters systemic bottlenecks, such as insufficient sorting technology for post-consumer
waste. In contrast, chemical recycling (feedstock) is concentrating investments as a solution, requiring low input-
characterization. Additionally, design for recycling trends might reduce multilayers’ complexity. A gap between
recycling targets and recycling technologies was identified, representing short-term opportunities for more
sustainable materials, such as bio-based.

1. Introduction positive environmental benefits of a circular production model (Korhonen

et al., 2018).
Most manufactured plastic items are made of non-renewable mate Despite well-known environmental advantages, materials with recycling
rials, mainly fossil-based (Shogren et al., 2019). In a planet with finite potential still have inappropriate destinations, such as dumpsites; or less
resources, the intensive extraction of these materials to feed a linear desired ones, such as landfills and incineration with energy recovery
economic model of production, consumption, and disposal proves to be (Conversio Market and Strategy GmbH, 2019). Besides the shortage of
unsustainable (Ellen MacArthur Foundation, 2017). Circular economy natural resources, plastic-related environmental issues often entail other
models have been studied as solutions to current and future environ environmental threats, such as land and sea pollution (Windsor et al.
mental challenges (Ghisellini et al., 2016). In this sense recycling is 2019). This is a common situation for plastic packaging materials, which
identified as a pillar, enabling materials to be reinserted in production have a short lifespan, large production volume, and various compositions;
chains (Nikanorova and Stankeviÿciene, ÿet2020;al., 2017).
RantaUnder
et al.,this
2018; Fellner creating challenges for their waste management (Huysman et al., 2017).
perspective, plastics materials used in packaging and other applications In Europe, plastic packaging represents 39,6% of the plastic demand,
require a well-functioning recycling process to shift from a linear flow to a while a great part of that becomes waste just after the use (Plastics
cycle (Picuno et al., 2021). Reduction of natural resources extraction, Europe, 2020).
waste production and carbon emissions are Nevertheless, plastic packaging is essential in some applications.

* Corresponding author. ¨

E-mail addresses: ctdms@[Link] (C.T.M. Soares), monicaek@[Link] (M. Ek), [Link]@[Link] (E. Ostmark), [Link]@[Link] (M.
Gallstedt), ¨ sigbritt@[Link] (S. Karlsson).

[Link]
Received 1 April 2021; Received in revised form 30 June 2021; Accepted 2 September 2021
Available online 28 September 2021
0921-3449/© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY license ([Link]
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Packaging is employed for different purposes, such as containing, pro Table

tecting, communicating with the customer, and branding the product 1 Some materials applied on MMPP packaging (adapted from Lamberti et al.
(Klimchuk and Krasovec, 2013). Moreover, the evolution of plastic 2020, Reichert et al. 2020, Kaiser et al. 2018 and Mieth et al. 2016).
production technology allowed the creation of packaging comprising Material Layer Application
different materials in a single structure, through many layers (Walker et Functionality Example
al., 2020). Consequently, multi-material multilayer plastic packaging Synthetic Polyethylene (PE) - heat-sealable Beverage cartons
(MMPP) enabled the industry to minimize the average thickness of Polymer - moisture (usually contains
(fossil barrier - LDPE layer)
packaging materials while combining functional properties, such as
based combination
barriers, mechanical strength, and heat tolerance (Mieth et al., 2016). As
sources) with gas/aroma
a result, MMPP became important for various applications, avoiding the barriers (e.g., PA,
overuse of materials and its consequential costs or the insufficient use EVOH) - moisture
and products’ losses (Anukiruthika et al., 2020). Polypropylene (PP) barrier - coated Toiletries,
with heat seal cosmetics,
However, MMPP embedded heterogeneity became a hindering factor
coatings (PVDC, microwavable
for the recycling industry (Walker et al., 2020). Waste characterisation is acrylate) for food packaging
key for the efficiency of mechanical recycling steps with high-quality end- mechanical
products (Garcia and Robertson, 2017) and conventional waste strength -
management systems are not adapted to identify, sort and recycle multi- combined with
gas/aroma barriers
material multilayers (Kaiser et al., 2018). Therefore, MMPP became a
- gas/aroma
difficult to recycle material; thus, a circular economy chal lenge (Mulakkal barrier - moisture
et al., 2021).
In this sense and motivated by the packaging industry need to shift
from a linear to a circular approach, this work identified and assessed Polyethylene Food packaging
terephthalate (PET) such as bottles,
possible techniques that are being considered for multi-material multi meat, or cheese
layer packaging recycling in a global perspective, when at least one of barrier
the components is a plastic polymer. Furthermore, trends that are likely - mechanical

to evolve in the field in the next five to ten years were studied with the strength - heat-
sealable
ultimate goal to enhance recycling knowledge. Printable outside
Polystyrene (PS) - gas
permeability - layer for fresh food
1.1. Multi-material and mono-material multilayers printability - packaging
combined with
gas/aroma
Multi-material multilayer structures consist of more than one layer of
barriers -
distinct materials where the components are layered to form flexible Polyvinyl Chloride gas/aroma Stretch wrap
packaging (pouches, bags, shrink films, other pliable products) or rigid (PVC) barrier -
ones (trays, cups, containers, other rigid plastic sheets) (Wagner, 2016). mechanical

This type of packaging is widely applied in the FMCG (Fast Moving strength - gas/
Polyamide (PA) aroma barrier Thermoformed
Consumer Goods) industry, in items with a relatively low-cost price and - mechanical food packaging
with a relative short lifespan, like beverages, food, and toiletries (Cooper, strength - heat-
2013). It is estimated that MMPP account for 26% of the flexible sealable -
packaging market by weight (Ellen MacArthur Foundation, 2017). oxygen barrier
Ethylene vinyl alcohol Oxygen sensitive food packaging
(EVOH)
Packaging for fresh food products may consist of four to seven layers Ethylene-vinyl acetate - adhesive Interlayer to bond
of different components (Butler and Morris, 2016). A wide range of (EVA) - heat- sealable PE to PVC
substances with different physical and chemical characteristics form Polyurethane (PUR) - adhesive (dry Cosmetics,
bond lamination) pharmaceutical
multi-material multilayers (Mieth et al., 2016). Various polymers are
- heat- sealable packaging
applied, such as polyolefins PE and PP and chemical variants (HDPE, - gas/aroma
LDPE, LLDPE, OPP), or polyesters such as PET and PLA. (Kaiser et Polyvinylidene chloride barrier Film wraps
al., 2018). These multilayer multi-material films and sheets are developed (PVDC)
by co-extrusion or lamination techniques (Wagner and Marks, 2016). An - moisture
barrier -
overview of the main materials, their functionalities and applications are
abrasion
shown (Table 1).
protection
In multi-material multilayer packaging, the use of different materials Synthetic Polylactic acid (PLA) - gas/aroma Cups, containers,
in different layers is connected to functionalities and packaging per Was barrier take-away
based - moisture packaging
formance needs (Table 1). Packaging design demands include adequate
polymer barrier
strength to contain and resist impacts (Robertson, 2016). Additionally, - mechanical
sealing performance plays an important role in preserving the product strength
and avoiding deterioration. Therefore, protecting the goods from abra Bio-Polyethylene (Bio - heat-sealable Similar uses as
sion, moisture, oxygen, light, odor, flavor, and chemicals; can be ON) - resistant to fossil fuel PE (uses
hydrolysis/ the same recycling
essential for packaging performance (Ragaert et al., 2020). Moreover,
oxidation stream)
high-speed equipment requirements for packaging production can
- flexibility -
include specifications of rigidity, pliability, and heat resistance, being Polyhydroxyalkanoates gas/aroma Applications in
fundamental for a flawless packaging engineering (Hahladakis and (PHASE) barrier - development -
Iacovidou, 2018). moisture may replace PET
barrier -
Another type of multilayer packaging can be produced with different mechanical
layers of the same polymer, that is chemically modified to reveal slightly strength
distinct functionalities and denominated mono-materials multilayers (continued on next page)
(Pettersen et al., 2020). Differentiation of molecular characteristics

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Table 1 (continued ) allows MMPP recycling in one stream (Lahtela et al., 2020). Addition ally,
Material Layer Application
an emerging recycling route is through chemical processes such as pyrolysis
Functionality Example with the production of feedstock, that do not require the sep aration of layers
(Solis and Silveira, 2020).
Polyethylene Furanoate - gas/aroma Applications in
(PEF) barrier development - A simplified roadmap for plastic packaging shows the recycling paths
- moisture may replace PET and the possible end-products through the value chain (Fig. 1).
barrier -
Diverse studies and new technologies aiming to improve plastics
mechanical
recycling are in development, and unknown treatment methods may arise in
strength - light
Other Aluminium Foil barrier - gas/ Oxygen sensitive
the following years (Mumladze et al., 2018; Vollmer et al., 2020; Solis and
materials aroma barrier foods packaging Silveira, 2020). In this sense, recent studies have suggested that enzymes
secreted by some microorganisms may bring insights to depolymerization
- moisture
processes while exploring the possibilities to degrade PET to its monomers
barrier -
mechanical
(Knott et al., 2020). These innovative methods can facilitate the degradation
Paper or paperboard Beverage cartons
strength - and recycling of MMPP structures in the future (Taghavi et al., 2021).
abrasion
resistance

1.2.1. Delamination
Multi-material multilayers may include adhesives for bonding in terlayers;
allows modification of physical, mechanical and barrier properties.
thus, recycling can include delamination steps (Horodytska et al., 2018).
However, this type of packaging usually has limited properties, such as
Zhang et al. (2015) studied a post-consumer liquid pack aging board
limited barrier performance or seal-ability properties; and may be un able of
delamination through bonding damage. Acetone was the solvent used by
meeting packaging requirements (Anukiruthika et al., 2020). On the other ´

Favaro et al. (2013) to delaminate

composition.
foodThe
packaging
application
withofPE/Aluminium/PET
physical processes
hand, considering that mono-materials are more homogeneous than multi-
to delaminate multilayers is unusual due to the bonding’s strength; however,
material multilayers, conventional recycling systems can usually absorb
basic structures could be separated by shredding and washing (Perick et
their flows (Ragaert et al., 2020). For this reason, there is a growing pressure
al., 2016). Kaiser et al. (2018) and Anukiruthika et al. (2020) summarized
on the packaging industry to abolish or decrease the use of multi-material
delamination techniques and patents dating back to the 1990s to separate
multilayer packaging, under the statement that mono-materials would be
layers; however, no commercial treatment in industrial-scale was currently
able to be managed with current recycling methods (Picuno et al., 2021).
identified (Walker et al., 2020). Innova tive technology is being developed
Trends towards mono-material packaging have increased, especially in
by the German company (Saperatec GmbH, 2021) to establish a low-energy
Europe, with CEFLEX Consortium (Circular Economic for Flexible Packaging)
material recycling process to
and more than a hundred stakeholders in the packaging value chain
(CEFLEX, n.d.). The organization has launched a series of voluntary
guidelines denominated “Designing for a Circular Economic (D4ACE)”,
aiming to help current systems to recycle flexible packaging (CEFLEX,
2020). Design for recycling includes the maximization of recyclable
components in the structures, avoidance of hazardous materials or non-
recyclables, reduction of complexity, among other efforts to increase
recyclability (Maris et al., 2018). Other tools to foster the design of more
recyclable packaging materials are being launched, such as “Recyclass”,
which assesses compositions of pack aging and suggests best practices for
recyclability (Plastics Recyclers Europe, 2020). Similar initiatives are being
developed willing to in crease the harmonization of packaging materials.

1.2. Status and advanced recycling technologies

In general, the MMPP recycling is complex since the recycling in dustry

is not able to identify, sort and separate the diverse layers with current
standard technologies (Horodytska et al., 2018). Therefore, MMPP is usually
sorted as mixed plastic waste in post-consumer streams (also called other
types of plastics) and frequently incinerated with en ergy recovery in
European countries, which does not prioritize recycling as a circular
economy practice (Kaiser et al., 2018). In low-income countries, these
packaging materials are usually disposed on dump sites or landfills
Conversio Market and Strategy GmbH, 2019) and a fraction also leaks to
the environment due to the common lightweight and short lifespan
(Hahladakis and Iacovidou, 2019).
As solutions, there are two main advanced methods to recycle MMPP. Fig. 1. Plastic packaging value chain and its recycling routes, including exist ing
The first one includes the detaching of the distinct components for further and emergent technologies. The production of plastic materials starts with raw
materials from fossil (most of the current production) or bio-based feed stocks.
treatment of materials separately; while another option is the processing of
Then, different processes are used to produce distinct types of pack aging. After its
all layers altogether (Kaiser et al., 2018). These methods prepare the
use and end-of-life, packaging materials are sorted according to the local infra-
packaging for further steps of recycling techniques. In this sense, MMPP
structure. If recycled, the usual recycling route for mono material plastic packaging
waste usually needs to be partially or entirely decon structed to become is through mechanical recycling. Other processes such as solvent-based techniques
recyclable and transformed into other products (Walker et al., 2020). If the and pyrolysis (represented by dashed lines arrows) are emerging alternatives for
structure is separated, delamination or se lective dissolution are possible difficult to recycle materials, such as MMPP.
treatments. Otherwise, compatibilization

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delaminate MMPP. This process includes a shredding step followed by a However, the technology might evolve as a future feasible option for plastics
microemulsion with a surfactant that promotes layers’ separation (Chen et or plastics-containing waste that is difficult to be materially recycled from an
al., 2021). According to Saperatec, the technique can delaminate structures economical and systematic perspective, opening new routes and
such as PE/Aluminum, PP/Aluminum, and PE/PET by mini mizing interlayers opportunities (Plastics Europe, 2020).
forces (Saperatec, n.d.). Vollmer et al. (2020) remark that it would be an A study developed by Solis and Silveira (2020) assessed eight tech
innovative category of separation since it does not dissolve completely the nologies regarding feedstock recycling for mixed plastic waste and their
forming polymers. Similarly, an Australian company, “PVC Separation”, technology readiness level (TRL). The most developed were pyrolysis,
developed a similar process to delaminate multilayers by swelling the catalytic cracking, and conventional gasification, whereas other emerging
polymer in a low boiling solvent and by the addition of hot water, the solvent technologies noticeably demand more investments to be at a commercial-
releases the desired polymers (Vollmer et al., 2020). stage (Solis and Silveira, 2020). BASF; Borealis; Unilever, Recycling
Technologies & Neste; and Sabic & Plastics Energy are ex amples of
companies developing the technology, investing on the suc cess of the
1.2.2. Selective-dissolution alternative as a plastics recycling future solution (Vollmer et al., 2020).
Selective dissolution techniques are another solvent-based method to However, it is still unclear how these processes would become economically
separate layers of MMPP. It takes advantage of polymers’ different sol and environmentally efficient (Ügdüler et al., 2020).
ubility, where a specific solvent dissolves targeted component and removes
materials in steps (Mieth et al., 2016). Thermoplastic polymers (PE, PP, PS,
PET and PVC) dissolution is an important technique used in recycling 2. Methodology
systems (Hadi et al., 2012). The solvent’s choice is an essential step of this
practice, while a range of solvents may allow the recovery of diverse layers This study included various methods, including in-depth interviews,
(Walker et al., 2020). Along the process, the target poly mer is dissolved, scenario planning, and an online feedback survey with experts (Fig. 2,
and other polymers remain at a solid phase; then, the solvent is used to Appendix 1). An in-depth interview is a discovery-oriented model that
target another polymer, or a different solvent can be used (Zhao et al., gathers comprehensive data beyond simple answers (Guion et al., 2011).
2018). Specific components of the multilayer structure can be selectively- The in-depth interviews followed open-ended questions and a semi-
dissolved for further recovery, with low contamina tion rates (Schlummer et structured format with conversational answer flow.
al., 2020). At least two initiatives are being developed in Europe, with the Scenario planning is a tool that develops a systemic understanding of
Fraunhofer Institute and APK AG, that use solvent-based solutions for an issue, using projected assumptions and elements necessary for those
¨

selective dissolution of polyolefins with further recycling (Vollmer et al., (Stormer et al., 2020).
interviews Data
with collected
experts on scientific
allowed literature
the scenario review
planning and
design.
2020). Recycling of beverage cartons using solvent-based techniques was Preceding the establishment of key elements (axes), this research identified
also evaluated (Georgiopoulou et al., 2021). These methods produce high- diverse factors that could affect the system; regarding economics,
quality end-products com parable to virgin materials (Schlummer et al., technology, society, or regulations. Then, two critical uncertainties were
2020) and show that solvent-based technologies are a realistic recycling defined for each of the axes as driving forces for the scenario matrix.
approach (Walker et al., 2020). Accordingly, possible future scenarios were established for each of the
quadrants.
Characteristics such as description; current facts; assumptions; stop/ slow
1.2.3. Compatibilization possibilities, qualitative impacts, and timeframe; were defined for each
Multi-material multilayers usually include polymer blends that are scenario.
mechanically unstable (Xie and Sui, 2020). For this reason, compatibi Various professionals deliberately collaborated on the interview and
lization uses chemical substances to increase multilayers’ mechanical survey stages, including experts from academia, brand-owners, plastics
stability and further recycle all layers in a single stream without sepa ration recycling industry, packaging industry, waste processing, flexible packaging,
(Mostafapoor et al., 2020). These methods make polymer blends less and circular economy organizations. Due to data protection required by
immiscible by adding another component to the structures (Ragaert et al.., interviewees, this study will not list the names of collabo rators. Generally,
2017). Compatibilizers are usually a blocky structure, chosen according to professionals of 26 backgrounds, including polymer science, packaging
the polymer blend, thus directly dependent on the com ponents of the engineering, plastic recycling, industrial economy, and sustainability, were
packaging (Ragaert et al., 2017). An innovative compa tibilization process contacted between October and December of 2020 on online settings.
is applied by the company “Dow” that incorporates compatibilizers within Moreover, experts’ experiences were mostly from a European and high-
the multilayer packaging (Dow, 2016). In this way, the packaging would income country perspective, including Ger many, Sweden, Denmark,
have a “self-recyclable” structure and a better performance against the Austria, and the UK. A few participants from the US also provided
addition of the additive on a separate recycling stream (Dow, 2021). assessments. Some participants were from low income countries, such as
Brazil, Indonesia, and African countries (not specified). The selection of
experts was based on a holistic and targeted analysis, comprising distinct
1.2.4. Feedstock recycling perspectives, which included waste man agement and packaging specialists
An alternative emerging treatment for difficult to recycle plastic waste from different parts of the world.
might be producing chemicals and fuels such as monomers or hydrocarbons Furthermore, the online survey combined a background explanation
feedstocks. Processes known to perform this are gasifi cation, pyrolysis, regarding the scenario matrix with open-ended questions to gather feedback
fluid-catalyzed cracking, and hydrocracking (Ragaert et al., 2017). Pyrolysis from experts. The survey included questions motivated by the
may become an active technology for plastic waste that is complex to be
depolymerized such as MMPP (Thiounn and Smith, 2020). The process
occurs in high temperatures and absence of oxygen when polymers are
broken down and, with further processing, result in petrochemical feedstock
such as naphtha or diesel (Ragaert et al., 2017). This process known as
chemical recycling include ther molysis through catalysts to selectively
generate gases, liquids, or waxes, and are new developments that go
beyond mechanical recycling (Garcia and Robertson, 2017). Until the
present, this is not a widespread recycling practice due to energy costs
(Solis and Silveira, 2020). Fig. 2. Structure of the sequence of methods applied.

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scenario matrix. The questionnaires were sent out by email, and a deadline
was established. Experts could access it and the background information
at any time within the timeframe selected.
The first open-ended questions asked for specific feedback on each of
the four scenarios “What are your thoughts towards scenario 1/2/3/4?”.
The subsequent questions were:

Q5. From the scenarios mapped, which one do you think is more likely
to be developed in the next 5–10 years? Where? Why?
Q6. Would you mention any other possible scenario for the future of the
recycling of multi-material multilayer plastic packaging? Which one?
Why?
Q7. What are the most critical factors to be described in each scenario?

Q8. What did you think about the critical uncertainties chosen?
Would you define another key factor as more relevant for the future of
multilayer packaging recycling? Why?

A final line for additional comments and opinions was also included. Fig. 3. Scenario matrix for the future of MMPP recycling, considering sorting
A Search Engine Optimization (SEO) tool was used for content technologies performance and recycling regulation pressure on the axes (x/y).
analysis and to process the qualitative data obtained in the survey. Scenario 1 represents the foreseen future when both factors are existent in a
(+/+) scenario; scenario 2 shows the future for a (-/+) case, scenario 3 a (-/-)
3. Results situation and scenario 4 a (+/-) situation.

3.1. Key drivers methodology.

Multiple driving forces that affect the future of multilayer plastic recycling • Scenario 1: High-performance recycling
were identified, such as: environmental benefits of the recy cling technology,
ability of use of recycled material in food-contact packaging, availability of A demanding recycling regulation combined with a high performance
collection/logistic systems, traceability of recyclates, volume of material to sorting technology (+/+) will shift the MMPP waste management towards
recycle, costs of recycling methods, costs of recycled materials, use of high-performance recycling, where the recycled material has similar quality
other alternative materials for pack aging (biodegradable, compostable), as virgin polymer.
increase of mono-materials, ban of plastics, consumer behavior, political
decisions, and others considered of less relevance for the scope of this (1) Facts: solvent-based techniques that perform high-performance
study. material recycling demand high-precision sorting and have high-
Then two key-drivers were chosen for the matrix, defined as critical for quality polymers as end-products.
the future of the recycling of multi-material multilayer plastic packaging: (2) Assumptions: sorting technologies will identify and differentiate multi-
material multilayer plastic packaging composition with high-precision,
including distinct layers. Recycling regulation will aim for high-
(1) regulatory pressure towards recycling and, performance processes.
(2) advanced sorting and separation technologies. (3) Slow/stop: trend into mono-material packaging could reduce MMPP
waste volume in the market, reducing the need for in vestments in
The first one was motivated by worldwide emerging regulations that sorting and treatment technologies. Constraints on technology,
seek to hinder plastic packaging waste and increase recycling rates. For costs, recyclate market, food-contact regulations hindering closed-
instance, in Europe, the EU Plastics Strategy requires all plastic pack aging loop recycling for these applications, new pri orities (e.g., COVID-19
to be reusable or recycled in a cost-effective manner by 2030, limiting other pandemic and uncertainties on sustain ability investments in some
destinations such as incineration and landfill (European Commission, countries).
2018). The Australian legislation is banning single-use plastics from March (4) Qualitative impacts:
2021 (EPA South Australia, 2021). Similar pres sures are being created in (5) Positive: tackle eventual costs due to the lack of plastic recycling
the UK; in some US states and in other countries, such as China, that have (EU plastic tax over non-recyclable plastics from 2021); decrease
packaging waste legislation planned for the upcoming years (Roland environmental impacts linked to other forms of disposal such as
Berger, 2020). incineration or landfill; increase of recycled material available on the
The second key element was motivated by the requirements of market, reducing its costs.
advanced recycling technologies. Since most of them demand a well known (6) Negative: high investments on new technologies, modification of
input of materials to perform an efficient treatment, high performance recycling systems including sorting logistics, costs of recycled
separation, and sorting is critical for a post-consumer recycling system. material; probable long timeframe until the technology is commercially
Projects in smart packaging such as digital marks for plastic sorting viable and spread out.
corroborated the assumption that better performance sorting technology is (7) Timeframe: 5–10 years.
needed to increase material recycling rates (e.g., Holy Grail project).
Scenario 2: Recycling into hydrocarbons (feedstock)
A demanding recycling regulation towards recycling and a lack of high-
3.2. Scenarios matrix performance sorting technology (+/-) will drive legislators to accept other
processes, such as chemical recycling into hydrocarbons (feedstock), as a
The scenario matrix shows the key drivers as main assumptions and valid recycling route.
comprises a range of possible future scenarios for the recycling of MMPP
(Fig. 3). Each scenario is described according to the described

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(A) Facts: diverse initiatives comprising feedstock recycling pro cesses (C) Slow/stop: consumer awareness and pressure towards more
and aiming to be a feasible solution for plastic waste are being innovative solutions, global trends towards a genuine and sus
developed worldwide. tainable circular economy with multiple cycles of recycling, decrease
(B) Assumptions: directives and legislations will allow the classifi cation of costs of other recycling alternatives.
of feedstock recycling streams as recycling, once the final products (D) Qualitative impacts:
can be used for plastic production and contribute to the circular
economy. Positive: tackle costs connected to the lack of plastic packaging recycling
(C) Slow/stop: high energy consumption, uncertainties about the genuine (e.g., EU plastic tax); possibility of production of new material products;
environmental benefits, high investments, lack of recy clate’s reduction of material consumption to produce items; low costs compared to
traceability in the recycled product. high-performance material recycling, technology already established in
(D) Qualitative impacts: some regions, feasibility at low-income countries.
(E) Positive: tackle eventual costs due to the lack of plastics recycling Negative: do not permit the recycling of materials diverse times,
(e.g. EU plastic tax); avoid the need for high-precision sorting lacking contribution to a continuous and strong circular economy.
logistics and its costs; feedstock produced can be allocated for
different purposes; opening of new treatment routes and avoid ance (A) Timeframe: < 5 years.
of plastic leakage to the environment.
(F) Negative: additional energy consumption for re-processing hy 3.3. Survey results
drocarbons into materials (if the feedstock is used to produce plastic
materials), costs of implementation, costs and logistics for up-scale, In the first part of the survey, the experts were consulted about their
costs of recycled material. opinions on each scenario. The answers showed that half of them expect
(G) Timeframe: <5 years. high-performance recycling to be developed in five to ten years’ future.
When asked about recycling through feedstock, experts mention that the
Scenario 3: Business as Usual (BAU) technology is already an active field. Various companies are testing it in
The lack of an established regulation towards plastic waste recycling some parts of the world, and 56% expect its development in the next 5–10
and the scarcity of separation and sorting logistics (-/-) will hinder changes following years. Regarding conventional solutions such as landfill or energy
in the management of multi-material multilayer plastic pack aging waste, recovery, the open-ended survey detected a desire that this scenario will
which remains the same, i.e., energy recovery, landfill, etc. not be part of the future. However, around 20% of the experts believe that
considering present trends, a ten years’ time-frame is a short-time to shift
(A) Facts: diverse low-income countries still lack effective plastic entire waste management systems in some countries. The background of
packaging waste regulation. In many countries, the reality con cerns these experts was mainly linked to low income regions. For the fourth
tackling dumping and environmental leakage, still far from high- scenario, 53% of respondents consid ered that low-performance recycling
performance sorting solutions. is likely to happen or keep happening in some parts of the world. As a more
(B) Assumptions: low-income countries will not change completely their established and cheaper material recycling technology, experts mention
plastic waste streams in the next few years; global packaging actors that downcycling is part of the solution, despite the lack of multiple-cycles
might take advantage of less regulated countries to keep doing recycling.
“business as usual”. For the second part of the survey, answers for question Q5 comprised
(C) Slow/stop: global cooperation towards the Circular Economy, a mix of scenarios expected for the future. The results included the
Extended Producer Responsibility (EPR) without country boundaries, scenarios below, in the same proportionality rate (18, 75% of opinions
innovation, recycling technologies with lower costs and adapted to received).
low-developed systems.
(D) Impacts: Positive: avoid extra costs for implementation of other • 1, 2,3 & 4 (all scenarios). •
technologies, avoid risks of change to a new technology that is not 1,2 & 4. • 2,3 & 4.
established yet.

Negative: eventual costs for non-recycled plastic (e.g., EU plastic tax), As seen, two of the most frequent answers do not include the business
environmental impacts of disposal process such as GHG emissions, as usual scenario, which might be a result of most experts’ European
pollution of soils, depletion of natural resources, etc.; leakage of plastic [Link] European socio-political context demands solutions that
waste to the environment, such as oceans. match local recycling targets and frameworks such as the new Circular
Economy Action Plan (European Commission, 2020). There fore, business
(A) Timeframe: <10 years. as usual solutions are not considered acceptable for the future, in this
perspective.
Scenario 4: Low-performance recycling (Downcycling) Regarding question Q6 and other non-mentioned possible scenarios,
A scenario where some sorting is available, and the regulation does not the main result was the possibility of alternative materials to substitute
compel the industry towards high-quality recycling (+/-) will drive the practice MMPP packaging, such as reusable or mono-material packaging, which
to a mechanical recycling path with low requirements and low-quality end- would reduce waste and consequent issues in the waste management.
products (downcycling). However, it is noticeable that this scenario mentioned does not include a
recycling solution, and, therefore, is outside of the boundaries of this study.
(A) Facts: some initiatives of post-consumer separation schemes for
flexible packaging perform mixed recycling and produce low quality Moreover, the answers to question Q7 showed that most respondents
products (as items for road construction, playgrounds, etc.). are concerned about identifying relevant legislation and regulation
frameworks associated to each scenario. It was considered essential that
(B) Assumptions: the lack of a strict regulation or governmental support life cycle assessments (LCA’s) of each technology are provided, detailing
for the recycling industry will prevent significant in vestments in new the holistic environmental impacts; also the overall implementation and
technologies of high-performance material recycling. operational costs.
Question Q8 regarded other key aspects for MMPP recycling rather
than the two axes established. The results showed the interest about

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recycled material costs and if the market will accept more expensive components than the plastic products, such as organic waste (Hahla
recycled materials. Local collection logistics availability was another dakis et al., 2018). Besides, around 40% of manufactured multilayer
key factor pointed by some experts; among others (Fig. 4). films inputs become post-industrial waste due to inefficiencies in cutting
and packaging manufacturing processes (Walker et al., 2020). These
4. Discussion fractions have low contamination levels, and the composition is more
straightforward to define than post-consumer (Huysman et al., 2017).
The following panorama illustrates future perspectives for the recy Some initiatives such as the solvent-based process “Newcycling”
cling of MMPP around the world, according to cross-linked analysis of devel oped by APK AG or the “Creasolv” by the Fraunhofer Institute
in-depth interviews, feedback survey and literature review (Fig. 5). are emerging technologies that recycle post-industrial fractions, still on
The answers emphasize that, at present, there is no expectation of small scales (Vollmer et al., 2020). Nevertheless, the feedback survey
a global mainstream solution for the recycling of multi-material multi showed that post-industrial recycled material does not have the same
layer plastic packaging . Distinct innovation projects are being devel acceptance in the recycling market as post-consumer recyclate. On
oped and tested for waste management systems in various parts of the other hand, post-consumer recycling initiatives such as the
the world. For this reason, the future will likely comprise a mix of Australian REDcycle includes partnerships with local supermarkets to
different recycling solutions. Advanced recycling treatment is being collect and mechanically recycle mixed flexible packaging (including
developed in high-income countries, while conventional solutions are MMPP), reducing the leakage to the environment (The REDcycle,
part of low income countries reality. Therefore, the difference in plastics 2017). Mixed recycling produces low-quality materials, such as trash
recycling technologies and treatment efficiency between high-income bags or land scaping items, and due to low mechanical properties,
and low income nations will persist in the next five to ten years. these materials frequently cannot be recycled again (Sheldon and
Additionally, countries in Europe need to find alternatives to MMPP Norton, 2020). In Australia and New Zealand, there are trends towards
and other non-recyclable packaging due to recently increased single-use plastics ban and downcycling recycling as a treatment for
pressures, such as the new plastic tax over non-recycled plastic, that flexible packaging (Wurm et al., 2020). In some low-income countries,
is active from January 2021 (European Council, 2020). Moreover, the downcycling is part of the current and future plastics recycling
Packaging Waste Directive (94/62/EC) includes ambitious targets of a panorama, significant for recycled material rates and important for local economie
minimum of 50% by weight of all packaging waste to be recycled by In addition, business as usual solutions are part of low-income na
the end of 2025 and 55% in 2030 (European Commission, 2018). tions future, which includes landfilling activities. In many of these
Additionally, the New Circular Economy Action Plan set a target countries, the applicability of packaging recycling regulation is inexis
requiring that all plastic packaging placed on the EU market must be tent or limited, and investments in plastic recycling technologies are
reusable or recyclable in a cost-effective manner by 2030 (European insufficient. However, the survey identified that new schemes are
Commission, 2020). These regulations foster the search within the starting to explore the possibility of high-income countries of investing
packaging value chain for new recycling routes and recycled materials. in plastic recycling projects in low-income ones (e.g., Verra 2021).
Within this window of oppor tunity, advanced recycling technologies On the other hand, mono-material solutions and pressures might
for multilayers and other non-recycled materials may evolve in the also affect the plastic packaging market. A mono-material multilayer
following years, especially in high-income countries, such as Germany. prac tical example is the “RecycleReady’’ launched by the company
Germany is alsoassociated with high contributions to the EU levy on “Dow” in the US, targeting the substitution of multi-material pouches
non-recycled plastics, based on Eurostat data (Eurostat (European for the alternative mono-material, offering “same properties” and an
Commission), 2020), which may speed the investments in high-performanceintegrated recycling system (Dow, 2019). The company “Borealis” also
recycling solutions.
In terms of feedstock recycling, the interviews and the survey un developed a mono-material multilayer structure made of different PE
veiled a mix of opinions amongst experts either supporting this solution layers, aiming recyclability, and relying on existing recycling methods
or those that do not believe that technology can bring real benefits, (Borealis, 2019). Following CEFLEX recommendations, the companies
economically and environmentally. Concerns about this technology “Nestl´e” and “Amcor’’ announced pouches for pet animals’ food made
include the high energy consumption, the operational costs and for of PP structure coated with an ultra-thin barrier while targeting the
scaling-up, the volume of material needed for scalability, and the recy main stream recycling of most European countries (Packaging Europe, 2020).
cled content’s traceability. Despite the uncertainties, feedstock recycling Nevertheless, this shift could bring other burdens such as decreased
is already an active field in some countries. Thiounn and Smith (2020) packaging quality, and product losses, such as food waste. Therefore,
mention that some companies are developing feedstock approaches such substitutions might be inadequate for some MMPP applications.
for chemical recycling of plastic waste. Germany, the Netherlands, the Moreover, for food-contact purposes, regulation and contamination
UK, and the US are some countries that may use this type of factors might hinder closed-loop mechanical recycling, which also in
cludes mono-material packaging recycling. Furthermore, alternatives
technology in the next few years (Vollmer et al., 2020; Solis and Silveira, 2020).
Furthermore, some experts highlighted the contrast between post to replace multi-material multilayer packaging usually comprise mono-
consumer and post-industrial MMPP waste flows. The waste produced material layers coated with additives (e.g., Dow and Borealis so
by the industry is prevailing cleaner than the post-consumer, which, in lutions). If this type of structure substitutes most of MMPP in the
contrast, is heterogeneous and highly contaminated with other market, they would probably increase contamination in conventional
mechani cal recycling, leading to a demand for additional recycling’
treatment steps.
Noticeably, the methods used in this study for data gathering;
including in-depth interviews, survey, scenario planning and future
foresight; include uncertainties. These consist of the subjectivity of
people’s opinions and assessments. For a more robust analysis, further
studies including quantitative data are recommended, such as LCA’s,
and cost-benefit analysis..

5. Conclusions

A complex system is characterized by various components, sub

Fig. 4. Other important aspects mentioned in the feedback survey. systems, and diverse interactions (Blomkvist and Johansson, 2016). In

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Fig. 5. Future of MMPP recycling according to the methods assessed.

this context, multi-material multilayer plastic packaging value chains are complex systems the European target of 55% plastic packaging recycling for 2030, based on current
that require holistic analysis; and steps of collec tion, separation and sorting are essential volumes of all plastics. Therefore, there is a gap between established recycling
to enable its recycling. technologies and the recycling targets, widening innovation opportunities for the use of
Therefore, these heterogeneous systems are not straightforward to be changed. more sustainable materials, such as bio-based.

Globally, multi-material multilayer plastic packaging is a solution for diverse packaging Ultimately, a great part of the world still lacks basic waste man agement and
requirements and uses. However, it also became an issue for the recycling industry due conventional recycling systems. As a result, even if Europe or few developed countries
to the difficulties of sorting, sepa rating layers and the high costs of treatment. Therefore, have the most efficient technology to recycle multilayers and other plastic packaging
this packaging material is usually disposed of in mixed plastic streams and further materials, global problems such as plastic pollution in oceans, carbon emissions from
incinerated with energy recovery or landfilled. plastic production and depletion of fossil resources will persist, as well as their conse
quences. To tackle some of these burdens, the increased use of bio-based materials in
Concerning the next five to ten years, more than half of the experts consulted in this MMPP and in overall plastic packaging can be a short-term opportunity to reduce carbon
study believe in the development of advanced tech nologies to recycle multi-material emissions and decouple packaging mate rials from the fossil-based economy. Hence,
multilayer plastic packaging waste, mainly in high-income countries. This includes high- the use of renewable ma terials in packaging materials can enhance the sustainability
performance ma terial recycling technologies with advanced sorting technologies, espe performance where multi-material multilayer plastic packaging is essential and its
cially in Europe. Further, chemical recycling solutions (feedstock) are an alternative with recycling is not available yet.
high-expectations for the future, mainly in high-income countries. The Facts 2020 Report
declared that a small fraction of plastics recycling is already being performed by chemical
recycling processes in Germany (0, 2%) and Italy (0, 1%) (Plastics Europe, 2020).

Declaration of Competing Interest

Therefore, this type of technology is expected to grow as a valid recy cling stream in the
The authors declare that they have no known competing financial interests or
next few years. Additionally, low-performance recycling (downcycling) is seen as part of
personal relationships that could have appeared to influence the work reported in this
the solution, contributing to reduce plastic leakage to the environment. Hence, the future
paper.
holds a mix of solutions for MMPP recycling, including all scenarios, also the less desired
one, business as usual. The treatment of this type of packaging material will depend on
Acknowledgment
local capabilities, regulations, investments, and priorities.

This work was supported by the Royal Institute of Technology (KTH) and the School
of Engineering Sciences in Chemistry, Biotechnology and Health, Department of Fiber
Additionally, to increase recyclability, it was identified a need for more integration
and Polymer Technology. Additionally, the guidance and support of Stora Enso was
and transparency amongst all actors in the packaging value chain. This means joint
essential for the development of this research.
efforts from various stakeholders regarding waste management actors, governments,
packaging industry, research institutions, brand-owners, and consumers, towards a more
harmonic system. Challenges such as the heterogeneity of local waste management
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