Advances in Structural Separation Technologies for Multilayer Packaging Recycling
Year: 2026
Type: article
Abstract: ABSTRACT Multilayer materials have become an essential part of modern packaging design. They are engineered to merge different materials into a single, lightweight structure. However, their recycling is challenging because the layers are strongly bonded and chemically heterogeneous. As a result, multilayer packages (MLPs) often bypass recycling streams, causing environmental pollution and resource depletion. A potential long‐term solution is represented by disassembly processes that separate layers and direct them into single‐polymer streams. This review examines studies on separation technologies and categorizes them by their dominant mechanism of action. Delamination techniques chemically remove or deactivate bonding layers, whereas selective dissolution‐precipitation (SDP) uses polymer‐solvent thermodynamic windows to dissolve and recover polymer layers sequentially. For solvent selection, we consolidated Hansen Solubility Parameters to produce polymer solvent compatibility and distance maps for common polymers. Additionally, a detailed comparison is made of recovery outcomes, technology readiness levels, and their impacts on recyclate purity and food‐contact safety. Structural separation offers a feasible approach to reintroducing post‐consumer MLPs into mechanical recycling, provided solvent management, contamination control, and regulatory compliance are properly managed. We recommend prioritized research into closed‐loop solvent management, energy reduction, and scale‐up validation of promising delamination and SDP methods.
Source: Advanced Sustainable Systems
DOI: 10.1002/adsu.70531
Authors: Aditya Chauhan, Andrea Fiorati, Luigi De Nardo
Institution: Politecnico di Milano
Language: English
Subfield: Polymers and Plastics
Field: Materials Science
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $4,430
OpenAlex ID: W7163905641