Researchers at ROSBIOTECH University have unveiled a novel method to recycle multilayer packaging film by grinding it through a specialized grinder. This process yields granules that can be used to manufacture new food packaging, challenging the long-held belief that multilayer films could not be repurposed after initial use. ROSBIOTECH shared these findings with socialbites.ca, highlighting a potential shift in how packaging waste may be managed in North American markets as well.
Multilayer films are among the most widely used polymer packaging materials today. They appear across sectors including food, agriculture, and pharmaceuticals, notably in the packaging of meat and prepared meals. In these contexts, the films are prized for their barrier properties and durability. ROSBIOTECH researchers carried out a series of tests to demonstrate that this type of packaging can be reprocessed into viable secondary materials without sacrificing performance.
During the experiments, the original multilayer films and contaminated samples were subjected to a sequence of operations that mimic real-world life cycles. Contaminated materials were cleaned, dried, ground, granulated, and then extruded into flat films. This sequence simulated production, usage, and subsequent recycling stages, providing a practical assessment of how recycling can be integrated into existing manufacturing streams, according to Irina Kirsh, head of the Department of Industrial Design, Packaging Technology, and Expertise at ROSBIOTECH, who spoke with socialbites.ca.
In the laboratory trials, the team processed film samples using extrusion technology that resembles the action of a meat grinder—but within controlled industrial equipment. The result was secondary raw materials in the form of 0.08 millimeter granules and thin films. The researchers found that these materials exhibited strong resistance to deformation and retained high structural integrity, suggesting their suitability for regenerating polymer products used in technical applications, including food packaging. The study points to the potential for a circular economy approach in packaging, where spent multilayer films re-enter the production cycle rather than ending up in landfills.
One notable finding concerns the presence of ethylene-vinyl alcohol copolymer within many multilayer structures. This component contributes to the overall strength of recycled products and enhances barrier properties, particularly oxygen resistance. Such attributes are valuable for maintaining product quality in subsequent packaging cycles and align with industry demands for reliable, recyclable materials in both North American and European markets.
Experts believe that these results could support greater adoption of recycled multilayer materials in Russian industry and beyond, potentially influencing packaging standards and recycling infrastructure across North America as companies seek sustainable alternatives. The implications extend to manufacturers looking to reduce waste, meet regulatory expectations, and communicate improved environmental performance to consumers.
While the initial findings are promising, scientists emphasize the importance of further validation across larger production scales and diverse material configurations. Real-world implementation will require collaboration among packaging designers, material suppliers, and processing facilities to ensure consistent quality and compatibility with existing systems. Nonetheless, the study adds to a growing body of research supporting the viability of recycling multilayer films and expanding the options for closed-loop packaging solutions in North America.
Preliminary research also highlights the broader context of packaging sustainability. Reprocessing multilayer films aligns with ongoing efforts to minimize waste, reduce the environmental footprint of packaging, and promote responsible consumption across industries. As markets continue to evolve, the ability to reintroduce recycled films into the supply chain could become a standard practice, helping brands meet consumer expectations for greener, more efficient packaging options. The ROSBIOTECH team plans to continue exploring processing parameters and material combinations to optimize performance and market readiness. The work signals a potential shift toward more robust recycling streams that can handle complex multilayer structures while preserving product safety and integrity.