Low-temperature catalytic delamination of metallized polyolefin films
A low-temperature, organocatalyst-enabled delamination process for recycling metallized polyolefin multilayer films. It selectively depolymerizes polar adhesive and functional layers while preserving polyolefin integrity, yielding a PE/PP-rich solids stream for melt reprocessing and recovering depolymerized fractions as reusable chemical intermediates. The approach also separates thin aluminum metallization as a fines stream to support a more efficient recycling pathway.
Overview
A low-temperature, organocatalyst-enabled delamination process for recycling metallized multilayer films. The method targets and depolymerizes polar adhesive and functional layers while preserving the integrity of polyolefin layers. It releases a clean PE/PP-rich solids stream suitable for melt reprocessing and recovers depolymerized fractions as reusable chemical intermediates. The process also separates thin aluminum metallization as a fines stream, supporting a more efficient and sustainable recycling pathway.
Technical specifications
Key features:
- Operates at temperatures below 200°C, reducing energy consumption compared to conventional methods.
- Uses a selective solvent/catalyst system that depolymerizes only contaminating layers, enabling high-purity polyolefin recovery.
- Supports closed-loop solvent and catalyst recovery to minimize waste and operational costs.
- Tolerates mixed feeds and multilayer structures, enabling processing across a range of film compositions.
Applications:
- Recycling of flexible packaging materials containing metallized polyolefin films.
- Recovery of high-purity polyethylene and polypropylene for reuse in manufacturing.
- Production of reusable chemical intermediates from depolymerized adhesive layers.
Technology readiness level
The technology is currently at TRL 4, having been validated at the kilogram scale and progressing toward larger-scale trials. Ongoing work includes aligning with target film structures, conducting bench-scale trials, and preparing for pilot-scale operations with potential industry collaborators. This supports rapid advancement toward proof-of-concept and eventual commercialization.
About Re-Du Company
RE-DU is a recycling technology company that has developed a patented process for the chemical deconstruction of mixed plastic waste. By breaking down diverse plastic types—such as PET, PC, PU, and PA—into monomers, the company enables the transformation of previously difficult-to-recycle materials into commercially valuable chemical products. This technology eliminates the need for costly sorting of mixed waste streams and offers an efficient, cost-effective alternative to traditional plastic management systems, which often rely on outdated processes that fail to address the majority of global plastic waste.
By providing a scalable solution for chemical recycling, RE-DU aims to reduce reliance on fossil fuels and minimize the environmental impact of plastic pollution in landfills. The company serves as a partner for industries seeking sustainable chemical feedstocks and is contributing to the development of a circular economy. Supported by initiatives like the Innovation Crossroads Award and research collaboration with Oak Ridge National Laboratory, RE-DU is positioned to help transition toward a net-zero carbon society by proving that mixed plastic waste can be successfully converted into high-quality, reusable resources.
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