BASF, Bobst and partners pioneer closed-loop recycling model for multilayer PET packaging

22 Jun 2022 --- BASF, Bobst, Evertis and Sulayr’s strategic partnership on a closed-loop recycling model for plastic packaging is sparking new discussions on what role PET-based multilayer can play in tomorrow’s packaging industry.

Kresimir Cule, commercial marketing industrial adhesives at BASF, tells PackagingInsights: “BASF is one of four partners who collaborated and communicated this recycling approach. The idea was to represent the whole value chain in this project, which is essential for later implementation.” 

“BASF delivers the lamination adhesive for production of multilayers while the other partners produce the basic film material and care for the lamination process (Evertis), offer the coating machinery able to handle water based systems (Bobst) and take care of the delamination and recycling process (Sulayr) – which is key for reuse of the PET.”

The European Green Deal requires all packaging to be reusable or recyclable by 2030 – a regulation that is perceived as particularly challenging for multilayer packaging since its layers first need to be separated before entering recycling streams. 

Multilayer recycling process
Sulayr, a recycling company operating in Europe, has successfully commercialized a multilayer recycling process that achieves “closed-loop” status and enables PET to be reused with virtually zero waste. 

With this, a circular economy practice for PET containing packaging materials already exists, but this process can be improved and become more practical and effective if the whole value chain works together with the target to make the separation of the layers easier, says BASF. 

The European Green Deal requires all packaging to be reusable or recyclable by 2030.Industrial adhesives company BASF, packaging machinery OEM Bobst and film company Evertis are supporting Sulayr in this project. Together, the companies form a strategic partnership combining expertise from across the entire packaging value chain. 

Their collaborative contributions are key to the success of this recycling process and its potential for adoption on a bigger scale, says BASF.

Hurdles for a circular economy
At the core of the recycling process is a multilayer film produced by Evertis, comprising PET and PE layers, laminated with a BASF Epotal water-based adhesive and processed with a Bobst coater. 

Multilayer films are used for various packaging materials. After use, the waste is delivered to sorting facilities. Sulayr can use the so-called waste as raw material, ensuring a closed-loop. Sulayr separates the multilayers and makes the PET available for reuse, with recycled PET delivered to Evertis and other film producers, who then restart the cycle.

BASF says this is an important step toward universal recycling of PET, enabling its continued use in a Green Deal-compliant packaging economy. The process can apply to post-consumer and post-industrial waste – meaning it has “enormous” potential to transform the entire PET-based packaging use model.

“Mono-PET material is easier to recycle and should be the choice whenever technically feasible, but for many applications, multi-layer PET trays are necessary to meet barrier or sealing requirements,” explains Cule. 

“From a technical point of view there are already existing technical options to realize recycling of PET-based packaging materials, also for so-called multi-layer tray material. And like Sulayr shows, it’s commercially realized on an industrial scale. Furthermore, at BASF we are working on a special type of lamination adhesives, which allow an easier debonding and separation of the single layers under certain conditions, very close to a standard PET washing process.” 

“However, from our point of view, the big challenge now is to bring all functions and parties together and define standards and processes for the whole packaging value chain, which allow for an integrated closed-loop recycling in future. Therefore, we think that this collaboration, which represents a big part of the value chain, proves that multi-layers can also have a bright and [environmentally] sustainable future.” 

The four partners emphasize that collaboration and cutting-edge technology are key to the success of the recycling process. Partnership is key
The four partners emphasize that collaboration and cutting-edge technology is key to the success of the process. 

Thomas Peter Schiele, vice president Adhesives, Fiber Bonding and Paper Coating Chemicals at BASF, comments: “This collaboration can be game-changing for the future of flexible packaging. It demonstrates that a circular economy for PET-based packaging is commercially possible – if we all work together. When it comes to recycling and debonding on multilayers we see good results with our water-based adhesives which can be key in this process, and we are confident that we can improve this process even further.”

“At BASF, we are working on special adhesives that enable even easier separation under certain conditions. The more we do to demonstrate the viability of the process, the quicker it can become standard for all lamination adhesives – which would take the recycling of multilayers to the next level.”

Rui Silva, chief product and innovation officer at Evertis, adds: “This cooperation is a best practice for the packaging industry and significant for the future of multilayer packaging materials. The requirements of the Green Deal compel us all to do everything within our power to scale up the sustainability of our products and to implement systemic changes to future-proof our industry. I am proud of the contribution this project makes to that goal.”

Hoping for wider industry change
Sulayr and its partners also hope to change industry perceptions on a wider basis. Multilayers based on PET are necessary for many industrial uses, but were not thought of as an environmentally sustainable solution – until now. This best-practice process could change the conversations about PET, waste, and environmental sustainability that are taking place within value chain leaders and packaging associations, such as Petcore and CEFLEX.

“We want to move forward, collaboratively as one industry, toward a sustainable future for all forms of flexible packaging. As a manufacturer of printing and converting machinery, we have a duty to contribute to a future-proof, recyclable solution,” says Sara Alexander, marketing and communication manager Flexible Packaging at Bobst. 

“We have done so by developing our equipment platform in terms of the most suited coating technology, process agility and speed with water-based adhesives to meet the project’s scope. Now, thanks to all the partners’ contribution, we have an opportunity to secure that future for PET-based multilayer laminates.”

“By collaborating and optimizing further with our respective technologies, solutions and expertise, we can close the loop on packaging material recycling and create a more circular economy for packaging that begins and reoccurs with end-of-life products,” concludes BASF.

By Natalie Schwertheim