‘Fully circular’ flexible packaging prototype to debut at K

Recycling process developer Saperatec will debut what is describes as a “fully circular” flexible packaging prototype based on its multi-layer delamination technique at K Show this year.

At Hall 9, Stand D17, Saperatec will show a detergent package which, at 35% post-consumer recycled content (PCR), meets goals proposed for the pending EU Directive on Packaging & Packaging Waste.

The prototype was produced in collaboration with film supplier Wentus – which makes a mono-polyethylene flexible packaging design that allows for easy recyclability – as well as adhesives group Henkel, which supplies the package’s recycling-optimised adhesive.

Henkel made a significant investment in Saperatec in 2019, which has helped make a forthcoming plant for the technology a reality. Currently marketed by Wentus as Wentoplex Pure R, the marketing design recently received 18 of 20 points from Germany-based recycling alliance Interseroh.

The prototype is made using Saperatec’s extended mechanical recycling process for thin-layer composite materials, which results in virgin-similar recyclates. A two-layer design made entirely from polyethylene (PE), its inner sealing layer comprises more than 50% PCR rLDPE from beverage carton waste. Its outer layer is printed with less than 50% surface coverage, and laminated with Henkel’s optimised adhesive for recyclability. Overall, the packaging will contain at least 35% PCR rLDPE – in line with the proposed recommendations for the EU Directive regarding non-food packaging.

Of the more than 140 million tons of plastics packaging waste produced globally each year, a significant portion comprises composite packaging, which consists of a combination of materials. Such packaging has posed sizable obstacles to recycling efforts, as separating composite packaging into its various origin materials has been technologically challenging and, even when successful, unsustainable due to the need for non-ecofriendly chemicals.

Saperatec says its approach results in recycled materials that can replace virgin raw materials in numerous applications, including film or foil-based packaging. Importantly, the process adds no contaminants to recycled polymers, and all chemicals used in the process comply with EU food contact regulations. Its technique is applicable for composite packaging comprised of various combinations of plastic, metal, and glass.

With the technology extensively tested in materials science labs and near-industrial pilot environments, Saperatec is currently building its first recycling plant for composite packaging in Dessau, Germany. In 2023, the facility will commence commercial operations with an initial goal of processing about 18,000 tons of packaging waste per year.

Saperatec’s composite packaging recycling brings the potential to separate and reintegrate a wide variety of substrates into the packaging stream. Initially, Saperatec will focus on composite flexible packaging materials and tube packaging with aluminum foil barriers, as well as plastics and aluminum from beverage cartons. Beyond that, Saperatec’s technology opens the door for future recyclability solutions in a wide range of composite packaging.

Importantly, Saperatec’s recycling process is sustainability-minded. The hot-wash separation fluids utilised are water-based and solvent-free, and are reused more than 30 times in the process. Any and all materials employed during packaging recycling are listed for food contact materials without specific migration limit, per European regulations.