Innovative Manufacturing and Recycling Approaches for Multilayer Polymer Packaging: A Comprehensive Review
Kowsar Rezvanian, Habeeb Talha Shahan, Delaram Ghofrani, Vijaya Rangari
Abstract
Polymeric waste, particularly from multilayer packaging films, presents significant environmental challenges. These multilayer films are often not recycled due to poor material properties and low commercial value when processed as polymer blends. Multilayer packaging effectively combines different polymers to protect sensitive food products and extend shelf life, yet their poor recyclability often leads to incineration or landfill disposal, counteracting efforts toward a circular economy and reducing crude oil dependency. The complexity of these materials, coupled with current recycling challenges, significantly impedes commercial recycling and presents considerable obstacles to sustainability. While biodegradable polymers offer a potential alternative to non-biodegradable materials, their broader use in packaging is constrained by high costs, inadequate mechanical properties, and lower thermal stability. Despite these drawbacks, multilayer packaging provides essential benefits to products and consumers, making it impractical to ban their use. Therefore, developing effective recycling processes for multilayer packaging is crucial. This review examines the common polymeric materials used in multilayer packaging, their manufacturing approaches, and various recycling and biodegradation techniques, aiming to provide comprehensive information on improving the sustainability of these materials.