Multi-Layered Plastic packaging is 100 % Recyclable

Mr. Jeevaraj Pillai, Joint President-Packaging Uflex Ltd.

Today, plastic is everywhere in our lives. Maximum number food items are found either in plastic/ flexible packaging or rigid packaging. The convenience of Flexible packaging makes this a preferred choice compared to its nearest alternative which is either paper or Aluminium.

Flexible Packaging is good for mankind as it preserves & protect the food. Multi-Layer Packaging is considered as the suitable packaging materials as compared to common single layer films and are characterised by special properties …. Such as high barrier for water vapour, gases such as O2, CO2 and aromatics, as well as offers high mechanical strength, good sealability and resistance at low temperatures.

These properties of multilayer films are a result of the synergy of basic properties of the different polymers used …. Typically an outer layer for printing, a barrier layer and a sealant layer for heat sealing the packet and other layers depending upon the requirement.

However, it becomes difficult to recycle Multi-Layer packaging because the polymers involved in different layers have different melting points. The challenge is to bring these multi layers to a homogeneous form which can be melted homogeneously to flow together and form recyclable pallets.

Because of their poor recyclability, most of these multilayers are usually incinerated / landfilled, negating the circular economy. Uflex has devised a technology that renders Multi-layer Packaging recyclable despite the presence different layer polymers having different characteristics.

Uflex is now able to address the “End-of-Life” stage of the Life Cycle of a multilayer packaging film using a combination of four novel technologies that makes it possible to recover high-quality granules which can be used for an array of injection or extrusion molding products.

The 4-stage Improvisation which makes MLP Recyclable.

The Technology

Development of a special processing additive:

When two or more polymers are blended together often times they are not compatible with each other. Thus, the resulting blend has insufficient properties for most end uses.

Uflex has developed a special processing additive which can bring all these material to a coupling bond so that they can be melted on a single temperature. These are block copolymers, both blocks being compatible with one of the phases. These molecules tend to concentrate at the interfaces and stabilize them thus allowing finer dispersion of mutually incompatible pairs. It promotes interfacial adhesion between pair of polymer which are otherwise immiscible, it also stabilizes its morphology.

Development of 2 stage extruder screw :

The extruder screw is the heart of the machine. Uflex has developed special two stage screws …. The first works as a conventional screw by feeding, melting, and conveying the polymer forward. The second screw does the same, except it is melt-fed by the first screw. This arrangement also provide devolatilization zones where the melt pressure is completely dissipated, so that volatiles can be extracted from the barrel.

Granulation face cutting technology

The hot granulation of thermoplastic materials is carried out directly on the extrusion surface, consisting of a die with several holes, on which acts a cutting device with blades. This device has the particularity of being able to vary and adjust the contact pressure of the blades on the surface of the die. Uflex has perfected a Die face cutting technology working on vertical axis which offers the advantage of a non-deviated flow of the melted material between the extruder and the die, with a consequent reduction in the loss of pressure at equal capacity, and elimination of the stagnation points of the finished product with uniform bulk density.

Degassing of Volatile Materials – Inks, Solvents, Adhesives & Moisture.

The degassing process is critical after a mixing section. Degassing enhances the homogeneity, physical appearance and cross-sectional uniformity of the extruded material.

Uflex has identified and provided the multi stage novel arrangement facilitating the escape of entrapped gases. The reduction in post-extrusion volatile content resulting from the inclusion of this arrangement, increase process efficacy and product quality.

End-Products :

The recycled plastic granules from the MLP waste, can be used in the injection moulding applications such as flower-pots, wastebaskets, tumblers, core plugs, road dividers, pallets, low-cost furniture, park benches and other daily use utility items.

There is a great deal of misconception, on plastic being the mere culprit to cause harm to the environment by choking the gutters, affecting the Marine life and harming the birds and animals which consume the littered plastics floating around both on the land and sea. But actually it is our littering habit which is the actually causing the harm. The absence of proper collection, segregation and recycling infrastructure is the root cause and not the packaging itself.

Globally billions of dollars are lost to the economy through failing to properly recycle Multi-layer plastics each year. Finding this solution represents a huge opportunity. We at Uflex believe that our commitment to making 100% of our packaging recyclable will support the long-term growth the global economy.

Uflex is contemplating all flexible packaging manufacturers to set up recycling units where Uflex will support these initiatives including providing necessary technology support and manpower training. Demonising and Vilification of Plastic Packaging, disregarding its contribution to the issue of food wastage and making food available to the remote corners of the world, has to STOP