Multilayered packaging

Multilayer packaging is a form of composite material that combines two or more distinct layers, each chosen for protective or functional properties. Typical materials include polyethylene (PE), polyethylene terephthalate (PET), polyamide (PA), ethylene vinyl alcohol (EVOH), aluminum foil, and paperboard. Multilayer formats are used in films, cartons, pouches, bottles, and tubes to extend shelf life, reduce spoilage, and provide mechanical strength.^[1]^[2]

History

Multilayer packaging was developed in the mid-20th century to overcome the performance limits of single-layer materials.^[3] An early example is the aseptic carton introduced by Tetra Pak in the 1960s, combining paperboard, polyethylene, and aluminium foil.^[3] In the 1970s and 1980s, multilayer films were adopted for vacuum pouches and heat-stable bags. By the 1990s, advances in lamination and coextrusion made them widely used in the food and pharmaceutical industries.^[4]

Types

Multilayer packaging varies by material combination and application.^[5]

Multi-wall paper sacks – layers of kraft paper, sometimes with polyethylene, for cement, fertilizer, and bulk foods
Laminated cartons – paperboard with aluminium foil and plastics, used for milk, juice, and syrups
Plastic bottles and tubes – combinations such as PET/EVOH/PE, used for sauces, juices, and cosmetics
High-barrier pouches – flexible laminates with PA, EVOH, or oxide coatings, used for sterilized or ready-to-eat meals

Food packaging

Multilayer systems are widely used for food preservation because they block oxygen, light, and moisture. EVOH is often used as an oxygen barrier, while polyolefins provide moisture resistance.^[6] Another application is modified atmosphere packaging (MAP), which replaces air with controlled gases such as nitrogen or carbon dioxide to slow microbial growth.^[7]

Manufacturing

Three main processes are used:^[8]

Coextrusion – simultaneous extrusion of polymers, often with tie layers
Lamination – bonding prefabricated films, foils, or paper layers with adhesives or heat
Coating – applying functional layers onto substrates,

End-of-life

Multilayer packaging is difficult to recycle because of its mixed-material structure. As of 2018 less than 5% was recycled at scale, with most waste incinerated or landfilled.^[9] Possible approach include solvent-based separation, compatibilizers, and enzymatic depolymerization of PET.^[10]

References

^ Mulakkal, M.C.; Ekins, C.; Wen, J.; Ramchandran, R.; Taylor, A.C.; Pimenta, S.; Charalambides, M.N. (2025-06-16). "Evaluation of Recyclable Multilayer Packaging Designs Utilising Controlled Interlayer Adhesion". Experimental Mechanics. doi:10.1007/s11340-025-01200-2. PMC 12446127.
^ Schmidt, Jannick; Grau, Laura; Auer, Maximilian; Maletz, Roman; Woidasky, Jörg (2022-04-29). "Multilayer Packaging in a Circular Economy". Polymers. 14 (9): 1825. doi:10.3390/polym14091825. PMC 9103501. PMID 35566994.
^ ^a ^b "Our heritage". www.tetrapak.com. Retrieved 2025-09-15.
^ Singh, Sonika (2020). Recyclability by Design for Multilayer Plastic Flexible Packaging. Lund University. pp. 9–13.
^ Tamizhdurai, P.; Mangesh, V. L.; Santhosh, S.; Vedavalli, R. (2024-04-01). "A state-of-the-art review of multilayer packaging recycling: Challenges, alternatives, and outlook". Journal of Cleaner Production. 447 141403. Bibcode:2024JCPro.44741403T. doi:10.1016/j.jclepro.2024.141403.
^ Bauer, Anna-Sophia; Tacker, Manfred (2021-11-05). "Recyclability and Redesign Challenges in Multilayer Flexible Food Packaging—A Review". Foods. 10 (11): 2702. doi:10.3390/foods10112702. PMC 8624454. PMID 34828983.
^ Seier, Martina; Archodoulaki, Vasiliki-Maria (2023-07-06). "Prospects for Recyclable Multilayer Packaging: A Case Study". Polymers. 15 (13): 2966. doi:10.3390/polym15132966. PMC 10346915. PMID 37447609.
^ Alreshidi, Maha Awjan; Yadav, Krishna Kumar (2025-07-01). "Advancements in the production methods and recycling of multilayer plastics with sustainable applications: A comprehensive review". Chemical Engineering Journal. 515 163633. Bibcode:2025ChEnJ.51563633A. doi:10.1016/j.cej.2025.163633.
^ Hahladakis, John N.; Iacovidou, Eleni (2018-07-15). "Closing the loop on plastic packaging materials: What is quality and how does it affect their circularity?". Science of the Total Environment. 630: 1394–1400. Bibcode:2018ScTEn.630.1394H. doi:10.1016/j.scitotenv.2018.02.330. PMID 29554759.
^ Soares, Camila Távora de Mello (2022-01-01). "Recycling of multi-material multilayer plastic packaging: Current trends and future scenarios". Resources, Conservation and Recycling. 176 105905. Bibcode:2022RCR...17605905S. doi:10.1016/j.resconrec.2021.105905.

External links

"Multilayer packaging: Innovative and sustainable". Extrusion-Info.
"Mono-material packaging: a ray of hope". Interpack.

[:7-1] Mulakkal, M.C.; Ekins, C.; Wen, J.; Ramchandran, R.; Taylor, A.C.; Pimenta, S.; Charalambides, M.N. (2025-06-16). "Evaluation of Recyclable Multilayer Packaging Designs Utilising Controlled Interlayer Adhesion". Experimental Mechanics. doi:10.1007/s11340-025-01200-2. PMC 12446127.

[:8-2] Schmidt, Jannick; Grau, Laura; Auer, Maximilian; Maletz, Roman; Woidasky, Jörg (2022-04-29). "Multilayer Packaging in a Circular Economy". Polymers. 14 (9): 1825. doi:10.3390/polym14091825. PMC 9103501. PMID 35566994.

[:11-3] "Our heritage". www.tetrapak.com. Retrieved 2025-09-15.

[4] Singh, Sonika (2020). Recyclability by Design for Multilayer Plastic Flexible Packaging. Lund University. pp. 9–13.

[5] Tamizhdurai, P.; Mangesh, V. L.; Santhosh, S.; Vedavalli, R. (2024-04-01). "A state-of-the-art review of multilayer packaging recycling: Challenges, alternatives, and outlook". Journal of Cleaner Production. 447 141403. Bibcode:2024JCPro.44741403T. doi:10.1016/j.jclepro.2024.141403.

[6] Bauer, Anna-Sophia; Tacker, Manfred (2021-11-05). "Recyclability and Redesign Challenges in Multilayer Flexible Food Packaging—A Review". Foods. 10 (11): 2702. doi:10.3390/foods10112702. PMC 8624454. PMID 34828983.

[7] Seier, Martina; Archodoulaki, Vasiliki-Maria (2023-07-06). "Prospects for Recyclable Multilayer Packaging: A Case Study". Polymers. 15 (13): 2966. doi:10.3390/polym15132966. PMC 10346915. PMID 37447609.

[8] Alreshidi, Maha Awjan; Yadav, Krishna Kumar (2025-07-01). "Advancements in the production methods and recycling of multilayer plastics with sustainable applications: A comprehensive review". Chemical Engineering Journal. 515 163633. Bibcode:2025ChEnJ.51563633A. doi:10.1016/j.cej.2025.163633.

[9] Hahladakis, John N.; Iacovidou, Eleni (2018-07-15). "Closing the loop on plastic packaging materials: What is quality and how does it affect their circularity?". Science of the Total Environment. 630: 1394–1400. Bibcode:2018ScTEn.630.1394H. doi:10.1016/j.scitotenv.2018.02.330. PMID 29554759.

[10] Soares, Camila Távora de Mello (2022-01-01). "Recycling of multi-material multilayer plastic packaging: Current trends and future scenarios". Resources, Conservation and Recycling. 176 105905. Bibcode:2022RCR...17605905S. doi:10.1016/j.resconrec.2021.105905.

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