Monomers
Mechanical recycling of polyamide-containing multilayer structures
Recycling of polyethylene/polyamide multilayer packaging is already state of the art
Multilayer packaging combines the specific advantages of different materials, providing optimal product protection while minimizing material use. For applications with demanding requirements regarding mechanical performance, barrier properties, and temperature resistance, such as packaging for sausages, cheese, and meat, PE/PA multilayer structures are therefore widely used. These structures can already be technically recycled through established recycling processes.
Recyclability of coextruded PE/PA films
Together with the Institute cyclos-HTP, BASF conducted independent studies demonstrating that packaging containing polyamide can be certified as recyclable.
As part of this assessment, PE/PA multilayer films were classified into three categories:
- Coextruded polyethylene/polyamide multilayer films
- Coextruded polyethylene/polyamide/ethylene vinyl alcohol high-barrier multilayer films
- Adhesive laminated polyethylene/polyamide films
Cyclos-HTP certificates
Packaging containing polyamide is still frequently classified as non-recyclable in various design-for-recycling guidelines. However, recent studies present a more differentiated picture: The independent Institute cyclos-HTP, together with BASF, has conducted a comprehensive investigation into the recyclability of different packaging structures containing PA.
The cyclos-HTP protocol assesses recyclability using original packaging under sorting and recycling conditions that reflect actual practice.
According to cyclos-HTP, PE/PA6 films can achieve a recyclability rating of 100% if the PE/PA recyclate is compatibilized by adding 0.15 g of compatibilizer per gram of PA6.
Conclusion:
According to the cyclos-HTP test CHI-C8-PEF-1, PE/PA multilayer structures are recyclable in Germany via recycling pathway 7 (PE-flex/MPO-flex) for flexible polyolefin or mixed-plastics fractions.
Certificates for the recyclability of coextruded PE/PA films (PA6 and PA6/6.6):
Example structure
Coextruded barrier packaging
PE/tie/PA
Certified:
Up to 30% PA6 / PA6/6.6+ PE-g-MAH:
Conditionally recycling compatible
PA6+ PE-g-MAH compatibilizer:
Valuable material; 100% recyclability
Certificates for the recyclability of coextruded PE/PA6/EVOH films:
Example structure
Coextruded high-barrier packaging
PE/tie/PA/EVOH
Certified:
Up to 30% PA6 and 5% EVOH+ PE-g-MAH:
Conditionally recycling compatible
PA6+ PE-g-MAH compatibilizer:
Valuable material; 100%(-%EVOH) recyclability
Certificate for the recyclability of adhesive-laminated PE/PA6 films:
Example structure
Adhesive laminated barrier packaging
BOPA//PE with PE-g-MAH compatibilizer
Certified:
Up to 23% PA6 / adhesive + PE-g-MAH compatibilizer:
Conditionally recycling compatible
Why is this topic so important?
The current strong focus on the mechanical recycling of household packaging and the promotion of so-called mono-material solutions often lead to the benefits of polyamides in high-performance flexible packaging being underestimated.
Important aspects such as reducing plastic consumption through lower material thicknesses, known as downgauging, the resulting reduction in packaging waste, and the extension of food shelf life through high-performance barrier packaging are often not sufficiently considered.
However, these properties make a significant contribution to the efficient use of resources and the reduction of food loss.
Guidelines & Regulations
CHI Recyclability Standard
The CHI Recyclability Standard sets out the design-for-recycling guidelines and the methodology used by the Institute cyclos-HTP (CHI) to assess the recyclability of packaging and other products. It explains the underlying assessment principles and methodology, which are based on many years of experience in the development and operation of recycling processes, as well as on the authors’ expertise as publicly appointed and sworn experts.
CEN-Standards for design for recycling
The European EN 18120 series of standards for Design for Recycling (DfR), developed by the European Committee for Standardization (CEN), was published in April 2026. It provides a structured methodology for assessing the recyclability of plastic packaging in Europe.
The standards were developed through an extensive technical process involving a wide range of stakeholders and expert review. They establish a common reference framework to improve the consistency and comparability of recyclability assessments across the European Union.
CEFLEX "Designing for a Circular Economy" Guidelines (D4ACE)
The D4ACE Guidelines provide practical recommendations for designing recyclable flexible packaging. They draw on the expertise of more than 150 experts and the assessment of over 600 packaging samples. The guidelines help companies systematically improve the recyclability of their packaging, prepare for future European requirements, and successfully achieve circular economy targets for 2030 and beyond.
Recyclability performance grades under the PPWR
The PPWR will gradually introduce mandatory Recyclability Performance Grades to assess the recyclability of packaging based on its Design for Recycling (DfR) score and the availability of recycling infrastructure across Europe, referred to as “recyclability at scale.”
Packaging will be classified into Grades A to D, with Grade A representing the highest and Grade D the lowest recyclability performance. The requirements will become progressively stricter with the transition deadlines in 2030, 2035, and 2038. From 2038 onwards, packaging classified as Grade C may no longer be placed on the market, while technically non-recyclable packaging classified as Grade D will be excluded from the market at an earlier stage.
The Recyclability Performance Grades are intended to promote innovation and support the development of packaging with improved recyclability, thereby contributing to a functioning circular economy.
Simone Schillo
BASF SE, Senior Manager Market Development Polyamides & Precursors Europe
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