Multilayer packaging recycling: challenges, current practices, and future prospects

Multilayer packaging, extensively used in the food, beverage, and cosmetics industries, offers excellent protection and durability by combining materials such as paper, plastic, and aluminum. However, its complex structure creates significant challenges in recycling, particularly in separating its layers. This review, conducted through a scoping analysis of peer-reviewed literature obtained from databases such as Google Scholar, PubMed, and ResearchGate, reviews the limitations of current recycling technologies, including mechanical, chemical, solvent-based, and enzymatic methods and highlights the experimental potential of microbial degradation as a future solution. It also explores innovative approaches, such as upcycling, biodegradable alternatives, and split-layer packaging, which reduce adhesive use and simplify recycling. Legislative frameworks and policy incentives are analyzed to underscore their role in driving technological advancements and fostering industry collaboration. Findings emphasize the absence of a fully viable solution with regard to recycling for multilayer packaging under existing technological and economic constraints. Although “Design-for-Recycling” and emerging methods such as microbial degradation offer promising long-term strategies, temporary measures such as advanced incineration or regulated landfilling may still be required. Moving forward, innovation in recycling technologies, supported by robust policies and collaborative industry efforts, is essential to align multilayer packaging with global sustainability goals and contribute to the development of a circular economy.