Chemical Recycling: Game-Changer for Multi-Layer Soft Packaging?

1. Limitations of Traditional Mechanical Recycling for Multi-Material Films 

Multi-layer soft packaging (e.g., snack bags, pouches) is notoriously difficult to recycle due to its hybrid composition of plastics, aluminum, and adhesives. Traditional **mechanical recycling** struggles to separate these materials, resulting in <5% global recycling rates. Contamination risks and degraded polymer quality further limit its scalability.  

2. How Advanced Chemical Recycling Works

''Chemical recycling'' breaks down polymers at the molecular level, bypassing material separation hurdles. Two leading methods:  

- Pyrolysis: Heats plastics to 400–800°C in oxygen-free reactors, converting them into pyrolysis oil for new plastics or fuels.  

- Enzymatic Depolymerization (e.g., ''Carbios''): Uses engineered enzymes to decompose PET into monomers, achieving 97% purity in 10 hours.  

3. Industry Collaborations Driving Innovation  

- Loop Industries: Partnered with L’Oréal and PepsiCo to produce 100% recycled PET from mixed plastic waste for packaging.  

- Eastman Chemical: Invested $1B in methanolysis plants to recycle 200M lbs/year of polyester waste by 2025.  

Brand Strategy: Cross-industry alliances reduce R&D costs and align with ESG goals.  

4. Regulatory Push in EU/US to Integrate Chemical Recycling

- EU Circular Economy Action Plan: Mandates 55% plastic packaging recycling by 2030, recognizing ''chemical recycling'' as compliant.  

- US EPA: Drafted tax incentives for pyrolysis facilities under the Inflation Reduction Act.  

 5. Environmental Impact Debates: Energy Use vs. Landfill Diversion  

Critics argue pyrolysis consumes 3–5x more energy than mechanical recycling. However, ''landfill diversion'' benefits are significant:  

- Lifecycle Analysis: Chemical recycling reduces CO2 emissions by 50% vs. incineration (BASF study).  

- Waste Reduction: 1 ton of chemically recycled plastic offsets 3.5 tons of landfill waste.