Delamination-driven disassembly of multilayer food packaging materials

Multilayer food packaging structures are designed for performance rather than recyclability, often using incompatible polymers and barrier layers that hinder material recovery. This leads to poor end-of-life outcomes such as landfilling or incineration. Here, we present an exploratory study on the feasibility of separating MLP into individual components for high-purity mechanical recycling. Representative structures, including PE, PP, PET, aluminium, and paper in laminated and vapour-deposited formats, were selected. The separation strategies investigated include solvent-assisted delamination, selective dissolution–precipitation, and mechanical–chemical pretreatments. A range of solvent and water-based formulations was screened to weaken adhesive and tie layers while preserving the integrity of the main polymers. The study evaluates parameters such as separation efficiency, material purity, and contamination. The aim is to support recycling for flexible packaging, especially for sensitive contact applications where material purity is crucial.