Recycling of multi-material multilayer plastic packaging: Current trends and future scenarios

Abstract Multi-material multilayer plastic packaging (MMPP) is widely applied in fast moving consumer goods (FMCG) combining functionalities of distinct materials. These packaging structures can enhance properties, such as resource-use efficiency and barrier performance leading to consequential benefits like a prolonged shelf-life. Nevertheless, they represent a challenge for existing recycling systems, confronting circular economy principles. This study aim was to foresight the future of recycling technologies for MMPP in the next five to ten years. Future scenarios were identified, including (1) high-performance material recycling, (2) recycling into hydrocarbons, (3) business as usual, and (4) downcycling. In-depth interviews and a feedback survey were methods used to validate the scenario matrix while defining experts' expectations towards the future. The analysis showed that distinct technologies will develop unevenly in different parts of the world. A mix of all scenarios is probable in the upcoming years, depending, essentially, on regulations and technology availability. Advanced high-performance material recycling encounters systemic bottlenecks, such as insufficient sorting technology for post-consumer waste. In contrast, chemical recycling (feedstock) is concentrating investments as a solution, requiring low input-characterization. Additionally, design for recycling trends might reduce multilayers’ complexity. A gap between recycling targets and recycling technologies was identified, representing short-term opportunities for more sustainable materials, such as bio-based.