Too many structures for the same function: Market evidence of circularity barriers in food packaging

The transition towards circular food packaging requires not only regulatory compliance but also material and structural harmonization. This study analyzes 163 multilayer films from commercial food packaging available on the European market to quantify structural diversity and assess implications for recyclability. Forty-two distinct multilayer configurations and twenty-seven polymer combinations were identified, with no systematic relationship to food category, film thickness, or functional requirements. Functionally similar packages frequently relied on materially incompatible or over-engineered polymer combinations, revealing a fragmented and non-standardized packaging landscape. Although all analyzed structures comply with current European food-contact regulations (EC 1935/2004 and EU 10/2011), their diversity and incompatibility hinder mechanical and chemical recycling, challenging the objectives of the forthcoming Packaging and Packaging Waste Regulation (PPWR). Overall, the results provide quantitative, market-level evidence of structural redundancy and demonstrate how fragmented design practices undermine design-for-recycling principles and the implementation of circular economy strategies in food packaging.