New Adhesive Technology Enhances Recycling of Multilayer Plastics

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News Summary

Researchers at Michigan State University have created an innovative adhesive that improves the recycling process for multilayer plastics (MLPs). This new solution addresses environmental issues associated with MLPs, which are commonly used in food packaging. The adhesive supports mechanical and water-based recycling methods, ensuring better material quality and potentially reducing plastic waste significantly. With its compatibility with existing manufacturing processes, this technology could bolster U.S. supply chains and create job opportunities while promoting sustainability in packaging.

East Lansing, Michigan — Researchers at Michigan State University (MSU) have developed a groundbreaking adhesive layer designed to enhance the recycling process for multilayer plastics (MLPs). This innovation aims to address the environmental challenges posed by MLPs, which make up approximately 30% of all packaging plastics and are particularly prevalent in food packaging due to their durability, extended shelf life, and affordability.

The new adhesive was created by Muhammad Rabnawaz, a professor in MSU’s School of Packaging and director of the NSF IUCRC Center for Plastic, Paper, and Hybrid Packaging End-of-Life Solutions. Traditionally, strong adhesives used to bond MLP layers have made these materials extremely challenging to separate and recycle, often leading to disposal through landfills or incineration. In fact, around 5 billion kilograms of MLPs used in the U.S. each year end up in such waste streams, contributing significantly to plastic pollution and resource depletion.

This innovative adhesive provides support for two primary recycling methods: mechanical recycling and water-based separation. While mechanical recycling is a cost-effective process, it can lead to lower-quality outputs due to material contamination. This may dramatically decrease the market value of MLPs from $5-$6 per kilogram down to as low as $1-$2 per kilogram. In contrast, water-based separation preserves the integrity of the materials, allowing for the extraction of high-value resins that can be reused for a premium of $6-$7 per kilogram.

Rabnawaz highlighted the balance they have struck between performance and economic value with this new technology. Importantly, the adhesive is designed for easy compatibility with existing manufacturing processes, meaning that companies can adopt the new solution without significant changes to their current production lines.

The formulation of the adhesive employs readily available materials that have been modified through proprietary chemistry to achieve optimal performance. The MSU research team has developed two versions of this adhesive technology: an initial version and a second, more economically viable formulation known as MSU MLP-2.

The potential impact of widespread adoption of this adhesive is substantial, with possibilities for significantly reducing plastic waste and emissions, which aligns with goals for climate resilience and resource preservation. Furthermore, this innovation addresses growing public health concerns regarding micro- and nanoplastic contamination in environments, including drinking water supplies and human health.

By facilitating the recyclability of MLPs, the technology aims to help mitigate the effects of microplastic pollution and encourage the closed-loop reuse of clean, food-grade materials. The adhesive is expected to bolster domestic manufacturing, strengthen U.S. supply chains, create job opportunities, and reduce dependence on imported materials.

Currently, the adhesive is progressing into a pilot phase, where it will undergo a 200-kilogram trial to evaluate its performance under commercial conditions. Discussions are also underway with potential licensees, setting the stage for broader industry adoption of the technology.

This recent advancement in adhesive technology has the potential to revolutionize MLP recycling processes, supporting sustainability objectives while adhering to newly emerging public health standards. With the continuous need for innovative solutions in the packaging sector, this adhesive represents a step forward in addressing one of the pressing issues in modern waste management.