Recyclable Packaging: From Tray-to-Tray Recycling to Fibre-Based Composite Solutions and Label Adhesives

The requirements for sustainable packaging will increase in 2026 – the EU Packaging Regulation (PPWR) comes into force on 12 August. Three current developments demonstrate how companies are driving the circular economy forward: optimised sorting processes for PET trays, new fibre-based packaging solutions incorporating recycled plastic, and recycling-compatible adhesives for PET bottles. Together, they illustrate how ‘design for recycling’ is increasingly becoming the norm.

PET trays pose particular challenges for recycling: complex material structures, a lack of take-back schemes and low recycling rates. The Spanish company Sulayr is focusing on industrial tray-to-tray recycling. Together with TOMRA, a process chain has been developed that spans from sorting to extrusion.

At the heart of the solution is the use of NIR sorting technology, which precisely identifies and separates different plastics. Complemented by flake sorting, purity levels of over 99.8% are achieved. This makes food-grade rPET (recycled polyethylene) possible – an important step for recycled materials in the packaging sector.

The result: higher material yield, consistent quality and new applications for recycled PET trays.

Dow and the RDM Group are taking a different approach: Multiboard CirculaRR combines recycled cardboard with certified, recycled polyethylene from advanced recycling.

The solution is:

• suitable for food contact
• suitable for applications such as frozen food
• compatible with existing paper recycling streams

With a plastic content of around 5%, the packaging remains recyclable whilst meeting functional requirements. Certifications such as ISCC PLUS and testing to 4evergreen standards confirm its suitability within the context of the EU Packaging and Packaging Waste Regulation (PPWR).

Their starting point: material combination rather than material substitution – with a focus on Design for Recycling and regulatory compliance.

Even seemingly minor components such as label adhesives have a significant impact on recyclability. With acResin® UV 3532, BASF demonstrates that high-performance pressure-sensitive adhesives can be compatible with existing recycling processes.

The adhesive:

• is certified by RecyClass
• enables labels to be removed cleanly during the recycling process
• supports the production of high-quality PET recyclates

This allows for the creation of highly transparent film labels without compromising recyclability – an important contribution to Design for Recycling and the requirements of the PPWR.

These examples illustrate just how diverse the approaches to improving recyclability have become – ranging from sorting technology and material combinations to individual packaging components. They reflect developments that are shaping international dialogue within the industry and are regularly showcased at K. Against the backdrop of regulatory requirements such as the PPWR, the circular economy thus remains a key area of focus.