Periodic Reporting for period 1 - ReMLP (ReMLP: Recycling Multi-Layer Plastic)
Reporting period: 2025-01-01 to 2025-12-31
"Multilayer plastics (MLP) are one of the largest unresolved waste streams: over 40 million tonnes are generated annually, yet current technologies cannot recycle them effectively due to their complex laminated structure and the presence of inks, adhesives, contaminants and mixed polymers. As a result, MLP is mostly landfilled, incinerated or leaked into the environment, while demand for high‑quality recycled polymers—especially food‑grade—continues to outpace supply. Existing solvent‑ or chemical‑based methods are slow, expensive, toxic, and incapable of producing high‑purity or food‑contact‑compliant materials.
ReMLP addresses this gap with a patented, water‑based delamination and steam‑stripping decontamination process capable of recycling any type of rigid or flexible MLP, including post‑consumer waste, and delivering food‑grade recycled polymers. The prototype plant (TRL6) has validated more than 10 MLP structures and generated early commercial traction with both recyclers and converters.
The project’s objective is to scale ReMLP to industrial pilot level (TRL8) by installing and optimizing a 500 kg/h pilot plant, validating its performance on the three largest MLP waste fractions (polyal, aseptic bags, flexible packaging), and initiate the process of obtaining EFSA food‑contact and UNE‑EN 15343 certifications. In parallel, the project will prepare the market for adoption through communication, customer engagement and pre‑commercialization activities, paving the way for TRL9 deployment at 1,000 kg/h.
The pathway to impact is straightforward: enabling recyclers and converters to convert currently unrecyclable MLP into high‑value, certified polymers unlocks new revenue, reduces disposal costs, and provides a scalable route to circularity. By 2029 ReMLP could prevent over 100,000 tonnes of MLP from landfilling or incineration, supply more than 90,000 tonnes of high‑quality recycled materials, and significantly contribute to EU circular economy and packaging‑waste targets."
ReMLP addresses this gap with a patented, water‑based delamination and steam‑stripping decontamination process capable of recycling any type of rigid or flexible MLP, including post‑consumer waste, and delivering food‑grade recycled polymers. The prototype plant (TRL6) has validated more than 10 MLP structures and generated early commercial traction with both recyclers and converters.
The project’s objective is to scale ReMLP to industrial pilot level (TRL8) by installing and optimizing a 500 kg/h pilot plant, validating its performance on the three largest MLP waste fractions (polyal, aseptic bags, flexible packaging), and initiate the process of obtaining EFSA food‑contact and UNE‑EN 15343 certifications. In parallel, the project will prepare the market for adoption through communication, customer engagement and pre‑commercialization activities, paving the way for TRL9 deployment at 1,000 kg/h.
The pathway to impact is straightforward: enabling recyclers and converters to convert currently unrecyclable MLP into high‑value, certified polymers unlocks new revenue, reduces disposal costs, and provides a scalable route to circularity. By 2029 ReMLP could prevent over 100,000 tonnes of MLP from landfilling or incineration, supply more than 90,000 tonnes of high‑quality recycled materials, and significantly contribute to EU circular economy and packaging‑waste targets."
"Throughout the reporting period, the project achieved significant progress in the development, optimisation and early validation of the ReMLP industrial pilot line. The full design of the recycling plant was completed, facilities were prepared, and all major equipment advanced through specification, procurement and pre‑installation stages. Experimental work carried out during this phase enabled important improvements in the performance and robustness of the process, ensuring smoother operation and higher efficiency across key steps.
Laboratory and pilot trials with the three targeted waste streams provided essential evidence on process behaviour and confirmed the technical feasibility of transforming these complex materials into high‑quality recycled polymers. These results guided several design refinements in preparation for industrial commissioning, particularly in relation to cleaning efficiency, material handling and process control. In parallel, the project established the full analytical and quality‑assessment framework required for certification, and produced initial recycled samples that were successfully tested with industrial partners, demonstrating promising performance in multiple applications.
Overall, the project has created a strong technical foundation, reduced risk ahead of industrial start‑up and reinforced the potential of the ReMLP technology to enable high‑value recycling of multilayer packaging at scale."
Laboratory and pilot trials with the three targeted waste streams provided essential evidence on process behaviour and confirmed the technical feasibility of transforming these complex materials into high‑quality recycled polymers. These results guided several design refinements in preparation for industrial commissioning, particularly in relation to cleaning efficiency, material handling and process control. In parallel, the project established the full analytical and quality‑assessment framework required for certification, and produced initial recycled samples that were successfully tested with industrial partners, demonstrating promising performance in multiple applications.
Overall, the project has created a strong technical foundation, reduced risk ahead of industrial start‑up and reinforced the potential of the ReMLP technology to enable high‑value recycling of multilayer packaging at scale."
"The project has delivered solid technical evidence that the ReMLP process can delaminate, decontaminate and recover polymers from polyaluminium, aseptic bags and flexible multilayer packaging, supported by optimized designs of the microperforation, delamination and decontamination units and by successful laboratory‑ and pilot‑scale tests.
Early extrusion trials with industrial partners show promising performance across several applications, while preliminary migration tests confirm global‑migration compliance and highlight specific contaminants that are already being addressed through improved washing and rinsing stages.
These results indicate strong potential impact by enabling recycling of a currently unrecyclable waste stream and producing higher‑value recycled materials. However, full industrial demonstration, further pilot testing to improve quality for demanding applications, resolution of specific‑migration challenges, stable access to feedstock and markets, and continued investment for industrial deployment remain essential to ensure successful uptake and large‑scale commercialization."
Early extrusion trials with industrial partners show promising performance across several applications, while preliminary migration tests confirm global‑migration compliance and highlight specific contaminants that are already being addressed through improved washing and rinsing stages.
These results indicate strong potential impact by enabling recycling of a currently unrecyclable waste stream and producing higher‑value recycled materials. However, full industrial demonstration, further pilot testing to improve quality for demanding applications, resolution of specific‑migration challenges, stable access to feedstock and markets, and continued investment for industrial deployment remain essential to ensure successful uptake and large‑scale commercialization."