Researchers are trying to redesign multilayer food packaging so it can be recycled or composted while still keeping food fresh. Today’s multilayer films often have 10 or more layers made from plastics such as polyethylene (PE), PVDC, PET, polyamides (PAs), and EVOH. These layers help block oxygen and moisture, add strength, and protect food, but they make recycling very difficult. Many films also include metal layers, which make them harder to process and can harm the environment when they are thrown away.
The main challenge is keeping the same strong protection that materials like aluminum, PVDC, and EVOH provide. These materials don’t mix well during recycling, and separating the layers is almost impossible. Chemical recycling can sometimes recover individual layers, but the recycled material is usually weaker. These processes are also expensive and energy-intensive, making them hard to scale up.
To solve this problem, the Bottle Consortium, supported by the U.S. Department of Energy, is using artificial intelligence (AI) and machine learning to help improve packaging design. Katrina Knauer, senior researcher at the National Laboratory of the Rockies, said the project brings together chemists, engineers, AI experts, and people who work with companies and consumers to make recycling better. AI can test many design ideas quickly and help find new materials that work with today’s recycling systems.
Rebecca Mick from the Association of Plastic Recyclers said companies spend a lot of time and resources trying to make packaging more recyclable. She explained that replacing PVDC and aluminum is difficult because few materials offer the same barrier protection while still being easy to recycle.
Early research shows new materials that do not contain chlorine or fluorine are getting closer to providing the same protection as PVDC. Knauer said more funding and testing are needed to develop prototypes and show that new materials can be safe, effective, and environmentally friendly.
With continued research and collaboration, multilayer food packaging could become easier to recycle, reduce waste, and still keep food fresh and safe for consumers.
12 March 2026
12 March 2026
12 March 2026
12 March 2026
