MERLIN Project's Innovative Approach to Recycling Multilayer Packaging in Europe

In 2022, Europe collected 32.3 million tonnes of post-consumer plastic waste, but only 37.8% of plastic packaging was recycled, while 44.9% was incinerated and 17.3% was landfilled. This situation is still far from the objective of recycling 55% of plastic in 2030, as established in the European Plastics Strategy and Directive (European Union, EU) 2018/852 on Packaging and Packaging Waste3. The demand for multilayer packaging poses a challenge in sorting plants, as current technologies can only detect the surface layer. Multilayer packaging, comprising incompatible polymer layers bonded with high-strength adhesive, often ends up in landfills or incinerators due to the complexity of separation methods. Addressing this issue, the MERLIN project focuses on identifying and recycling multilayer rigid, non-metalized flexible, and metalized flexible packaging. It tailors a specific recovery process for each type, separating and recycling plastic fractions and repolymerizing them for packaging demonstrators. The challenge lies in improving sorting and recycling processes for these plastics, particularly from post-consumer sources. Delamination, the process of separating layers, varies based on packaging nature. For non-metalized films, MERLIN employs green solvent-based processes. Hansen solubility parameters are studied to reduce interlayer interaction, achieving delamination through solvents under supercritical conditions (e.g., CO2) combined with green solvents. After these processes, different polyester and polyolefin fractions are separated and temporarily recovered. In essence, MERLIN aims to enhance recycling rates for post-consumer plastic waste, especially multilayer packaging, by developing tailored recovery processes and addressing challenges in delamination. The project aligns with European directives, striving to meet recycling targets and reduce the environmental impact of plastic waste.