A new report from the Circular Economy for Flexible Packaging (CEFLEX) initiative outlines five advanced recycling technology categories that promise to raise the quality of recyclates and make flexible packaging more recyclable than ever before. The research aims to support EU circular economy goals, including the ambitious target of recycling 55 % of flexible packaging by 2035.
Table of Contents
Rethinking the Recycling Toolbox
CEFLEX’s study emphasizes that no single solution can solve the challenges of flexible packaging waste. Instead, a mix of emerging technologies—used in combination—offers the most promise. The report spotlights 12 leading providers selected from over 20 projects, each offering scalable solutions that could hit full commercial readiness within five years.
These technologies are not intended to replace mechanical or chemical recycling or improved packaging design. Instead, they act as high-impact add-ons that can help recycle difficult waste streams that current systems struggle with.
Five Tech Classes Leading the Charge
- Advanced Wet Friction Washing: This technique tackles contamination before the extrusion phase, boosting material purity without breaking the bank. German firm HydroDyn leads here, with a patented single-stage mechanical washing process that delivers over 70 % material yield. Their systems already handle more than 100,000 tonnes across Europe.
- Delamination: Separating the layers in multi-material packaging is key to better recyclate quality. Saperatec’s 32,000-tonne-per-year plant in Germany is an early commercial example, using a water-based method for polyethylene-aluminum structures. Meanwhile, Spanish startup Fych is launching a 3,000-tonne facility with combined delamination, deinking, and steam-based decontamination.
- Deinking: Ink residues can seriously degrade recycled plastic. KEYCYCLE®, owner of the Cadel Deinking® process, offers turnkey systems that remove up to 95 % of external printing. The result: stronger, cleaner recycled plastics with improved color and reduced odor.
- Extraction: For applications needing near-virgin material quality, extraction is vital. France’s IPC is piloting a Supercritical CO₂ Purification technique aimed at producing high-purity recyclates. A demo plant is scheduled for 2025, with full-scale systems expected by 2027.
- Dissolution: This process separates target polymers in solution, generating ultra-pure outputs. APK’s Newcycling®, now under the LyondellBasell banner, runs a 12,000-tonne-per-year plant in Germany. U.S.-based PureCycle adds scale with a 49,000-tonne operation in Ohio and a second 59,000-tonne site planned for Belgium.
Infrastructure for a Circular Future
The report stresses that achieving true circularity requires more than just innovative recycling—it also demands a complete system overhaul. This includes better packaging design, smarter sorting methods, and the integration of advanced recycling technologies. By working together, these tools can align recycled materials supply with real-world manufacturing needs.
Conclusion
CEFLEX’s latest findings make one thing clear: the future of flexible packaging recycling lies in a multi-tech approach. By embracing a mix of advanced washing, separation, purification, and dissolution techniques, the industry can meet rising regulatory demands and shift toward a genuinely circular economy. The groundwork is being laid today, but full transformation will require rapid adoption and strategic investment in the years ahead.
