Closed-Loop Recycling of Shelf-Stable Multi-Layer Aseptic Packaging Components: a Novel Separation Method without Hydropulping

Pouya Shoaie and Alireza Bazargan ()
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Pouya Shoaie: University of Tehran
Alireza Bazargan: University of Tehran

Circular Economy and Sustainability, 2025, vol. 5, issue 3, 1963-1982

Abstract: Abstract Aseptic packaging refers to cartons made of paper, polyethylene, and aluminum layers that provide sterile packaging for products such as beverages, but recycling these multilayer laminates poses multiple challenges. Conventional recycling relies on hydropulping, which partially destroys and limits material recovery. This study demonstrates a new closed-loop process for recycling aseptic packaging through a chemical method without hydropulping. In this method, a solvent mixture of gasoline: xylene: toluene (50:25:25, v/v) is shown for the first time to completely dissolve the polyethylene and free the other layers. The dissolved polymer is distilled and converted back to pure LDPE. Dissolution efficiency is compared using different volumetric ratios and the effects of parameters including solid-to-liquid ratio, stirrer speed, time, and processing temperature are examined. By circumventing the paper pulping process and its associated issues and problems, the dissolution-distillation process enables reuse of all components of aseptic packaging in their original form. This approach, aided by solvent recycling, enables sustainable multilayer laminate recycling.

Keywords: Tetra Pak ®; Multilayer composites; Chemical recycling; Packaging waste; Aseptic cartons; Eddy Current Separation (ECS) (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1007/s43615-024-00496-x

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