Comprehensive characterisation of household packaging waste streams was completed across three demonstration sites in Spain (FCCMA), Italy (A2A), and France (SUEZ). The outcomes provide the first harmonised dataset on bio-based plastic prevalence at European scale. A NIR-based sorting program was developed, trained, and validated for the identification and separation of target bio-based plastics. The system was successfully tested on real Dutch municipal waste streams spiked with representative bio-based products (both films and rigids). This marks a significant advance beyond the state of the art, demonstrating reliable sorting of bioplastics within complex waste streams—an essential step towards closed-loop recycling of bio-based materials. Following initial sorting trials, pre-treatment protocol for bio-based plastics were established and validated to induce material loss and degradation but provide high-purity feedstock for downstream recycling. Lab-scale depolymerisation of PLA achieving high conversion efficiency and high purity of recovered monomers. In parallel, solvolysis process for polyester blends was advanced, with high recovery of bio-polyesters achieved even in the presence of 5–10% fossil-based contaminants. These breakthroughs extend the applicability of chemical recycling to complex, mixed waste streams and blended bio/fossil polymers—currently a key limitation in the field.
Furthermore, mechanical recyclability of PLA and BIOTEC blends through multiple extrusion–thermoforming cycles was demonstrated, maintaining acceptable mechanical properties after three recycling iterations. Complementary solid-state post-condensation (SSPC) trials indicated the potential for molecular weight recovery, thus enhancing material performance and extending product lifetimes. The first prototype product contained recycled PLA fractions, validating the potential to reintroduce these recycled materials into new packaging applications without compromising quality or processing performance. This confirms the technical feasibility of a closed-loop recycling route for bio-based plastics.
These results collectively represent a significant step beyond current industrial practice in sorting and recycling of bio-based plastics, offering validated methods and pathways for high-quality recycling compatible with both chemical and mechanical routes.
To ensure further uptake and large-scale success, key enabling actions include:
• Further demonstration at pilot and industrial scale to validate process robustness under real operational conditions;
• Standardisation of testing and quality criteria for recycled bio-based plastics to support market confidence and regulatory compliance;
• Integration into existing EPR (Extended Producer Responsibility) frameworks to incentivise collection and recycling of bio-based plastics.
• International dissemination and alignment with EU Circular Economy and Bioeconomy strategies to enhance market access and cross-border uptake.
Together, these advances position the project outcomes as beyond the state of the art in the circular management of bio-based plastics, paving the way toward a fully circular, low-impact bio-based packaging value chain.
