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Composite packaging, manufactured by laminating dissimilar materials together, provides mechanical and barrier properties that would be difficult to achieve with a single material. However, separating the various layers presents a special challenge to recyclers. Even when successful, such efforts can be unsustainable because of the chemicals needed for the delamination process.

has developed a mechanical recycling process for thin-layer composite materials made of plastic, metal, paper and glass. Encouraged by testing results, the company is currently building its first recycling plant for composite packaging in Dessau, Germany. The new facility is expected to commence commercial operations in 2023, with a target of processing 18,000 tons of packaging waste/yr.

The facility will start with a focus on composite flexible packaging material and tube packaging with aluminum foil barriers, as well as plastics and aluminum from beverage cartons. Other applications, including recycling of glass-polymer composites, are expected to follow.

According to Saperatec, the output from its mechanical process are suitable to replace virgin raw materials in film and foil-based packaging. The hot-wash separation fluids are water-based and solvent-free, and all materials used in its recycling process are listed for food contact per European regulations.

In October, Saperatec will highlight its new process at the K Show trade fair in Dusseldorf, Germany.