Extrusion International 6-2022

13 Extrusion International 6/2022 Strategic Partnership Delivers Best Practice Example of a Closed Recycling Loop for PET-Based Multilayer  Multilayer packaging based on polyethylene terephthalate (PET) can have a bright and sustainable future. This is the message of the strategic partnership of four leading technology companies, whose closed- loop recycling model is sparking new discussions on the role PET-based multilayer will play in tomorrow’s packaging industry. 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. However, that per- ception could be about to change. Sulayr, a recycling company operating in Europe, has successfully com- mercialized a multilayer recycling process that achieves ‘closed-loop’ status and enables PET to be reused with virtually zero waste. With this, a circular economy prac- tice 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. Industrial adhesives specialist BASF, packaging ma- chinery OEM Bobst and films expert Evertis are sup- porting Sulayr in this endeavour. Together, the compa- nies form a strategic partnership combining expertise from across the entire packaging value chain. Their collaborative contributions are key to the success of this impressive recycling process, and its potential for adoption at a bigger scale. At the core of the process is a multilayer film pro- duced by Evertis, comprising PET and polyethylene (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. The company separates the multilayers and makes the PET available for re-use, with recycled PET delivered to Evertis and other film producers who then restart the cycle. This is seen as an important step towards 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 en- tire PET-based packaging use model. Sulayr has been able to separate different types of multilayers since 2009, but the speed and cost-effec- tiveness of the process depends on the debonding of the films. Miguel Ángel Arena, CEO of Sulayr, said: “Our technologies enable us to delaminate most types of PET-containing multilayers and bring the recycled PET back to the industry. However, we see a difference in the trays coming from the post-use phase to our facil- ity. With BASF’s water-based Epotal ® adhesives for ex- ample, our separation process is simplified, because the adhesive allows a quick and easy separation with a high quality of the recyclates which is not the case with solvent-based adhesives for example. We are sure that a streamlined process can help scale up the recyclability of PET-based multilayers, giving the packaging industry a new way to meet its sustainability challenges.” One way to optimize the recycling process is to pro- duce all PET/PE trays under specific conditions that facilitate easy separation. This is an area in which the partners are collaborating: before bringing a new lami- nate to market, Evertis for example, qualifies it to be recyclable in Sulayr’s process, ensuring its layers can be separated easily. The four partners emphasize that collaboration, as well as cutting-edge technology, is key to the success of the process. 
BASF www.basf.com Bobst www.bobst.com Evertis www.evertis.com Sulayr https://sulayrgs.com