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Evaluation of Recyclable Multilayer Packaging Designs Utilising Controlled Interlayer Adhesion.

M C Mulakkal¹, C Ekins¹, J Wen¹

¹Department of Mechanical Engineering, Imperial College London, South Kensington Campus, London, SW7 2 AZ UK.

Experimental Mechanics

|September 22, 2025

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New multilayer packaging (MLP) designs facilitate layer separation for improved recycling. These innovative concepts replace traditional adhesives with localized adhesion or water-soluble alternatives, enhancing the circular economy for plastic packaging.

Area of Science:

Materials Science
Polymer Chemistry
Sustainable Packaging

Background:

Multilayer packaging (MLP) combines diverse plastics for demanding applications like food and pharmaceuticals.
Current MLP structures hinder effective recycling, limiting the use of recovered materials.

Purpose of the Study:

To investigate novel MLP designs enabling constituent layer separation.
To replace conventional thermoset adhesives with innovative bonding strategies.

Main Methods:

Evaluated layer adhesion using T-peel testing.
Simulated recycling processes (shredding, washing) to assess layer separation feasibility.
Investigated localized surface treatments and water-soluble adhesive layers.

Main Results:

Keywords:

Localised adhesion Multilayered packaging materials Plastic packaging Recycling Water-soluble adhesive layer

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Localized adhesion (Design A) allowed easy layer separation.
Water-soluble adhesive (Design B) enabled layer separation via dissolution.
Both methods demonstrated potential for improved MLP recyclability.

Conclusions:

Developed MLP concepts facilitate layer separation, crucial for recycling.
Localized adhesion and water-soluble adhesives offer viable alternatives to conventional MLP bonding.
Combining strategies could optimize MLP design for enhanced recyclability and performance.