Back to News

Multilayer packaging: innovative and sustainable

Photo: Innovative and sustainable multilayer packaging used for a specially sealed mozzarella packaging for ZOTT Gourmet Dairy

© Zott

BASF, Borealis, Südpack and Zott present prototypes of food packaging made from 100% recycled material

Multilayer packaging reliably ensures high-quality and fresh food products thanks to its properties. It protects the products and keeps them hygienic, thereby extending the shelf life of food. This is of particular importance in light of global food supply – one third of all food produced worldwide is spoiled before it reaches consumers’ plates. Smart solutions with multilayer packaging can play a part in reducing this unnecessary waste.

Multilayer packaging is sustainable: it does not require much material and can now also be produced from chemically recycled material.

“Today’s high-tech film packaging solutions consist of multiple materials and layers with different properties, such as an oxygen barrier. And thanks to the optimized use of materials, we were able to reduce the packaging volume to a minimum,” said Johannes Remmele, Managing Director of Südpack.

Multilayer packaging consists of up to 11 individual, ultra-thin layers, making it considerably lighter and thinner than comparable packaging. In addition to reducing the amount of raw materials used, this also contributes to considerably lowering CO2 emissions during transport. All in all, multilayer packaging is clearly more resource efficient than its alternatives.

However, multilayer packaging could only be recycled to a limited extent, because mechanical recycling processes are not suitable for composite materials. “Within the ChemCycling project, BASF is working on advancing the chemical recycling of plastic waste, because this will make it possible to process and reuse previously non-recyclable plastics such as mixed plastics. In collaboration with our partners, we have now for the first time produced a prototype packaging made of chemically recycled polyamide and polyethylene. This goes to show that the recycling of multilayer packaging could soon come full circle,” explained Christoph Gahn, who is responsible for the polyamide business at BASF.

This pilot project was made possible thanks to the collaboration between the four partners BASF, Borealis, Südpack and Zott. BASF supplies chemically recycled polyamide, while Borealis provides sustainably produced polyethylene. Südpack, one of Europe’s leading producers of film packaging for food products, uses these materials to produce multilayer film for a specially sealed Mozzarella packaging for Zott Gourmet Dairy.
Zott enjoys numerous benefits thanks to this multilayer film. “In our dairy, we continuously review the entire value chain to determine where we can be even more sustainable and how we can sensibly extend our sustainability standards. Now more than ever, customers expect that the packaging of their high-quality and sustainably produced food is as resource-efficient as possible. This is why it was important to us to be part of this pilot project right from the start in order to share our experience as well as our high-level requirements on packaging and its barrier functions, and to contribute to the development of a solution with identical functionality and increased environmental performance. We are very optimistic and hope that this project will make it to series production,” explained Andreas Strunk, Head of Production, Technology & Supply Chain Management at Zott.

“What is special about this pilot project is that both components of the packaging – polyamide and polyethylene – are made from chemically recycled material,” emphasized Maurits van Tol, Borealis Senior Vice President Innovation, Technology & Circular Economy Solutions. “This innovative solution came about thanks to the selection of special polymers. In addition, the collaboration between the companies involved made it possible for the first time to consistently certify each step up from the raw material to the finished packaging.”

The raw materials for polyamide and polyethylene were produced in very small quantities as part of the "ChemCycling" project. The pyrolysis oil derived from plastic waste was supplied by a partner and fed into BASF’s Verbund production site in Ludwigshafen as feedstock. According to the certified mass balance method, both plastics have an allocated 100% share of recycled materials.

More information on ChemCycling can also be found in the press release "New products from plastic waste" (P254e/19) and at: basf.com/chemcycling

Press contacts:

BASF
Daniela Rechenberger
Phone: +49 (0)621-60-40901
E-Mail: daniela.rechenberger@basf.com

Borealis
Virginia Mesicek
Phone: +43 1 22 400 772
E-Mail: virginia.mesicek@borealisgroup.com

Südpack
SÜDPACK Verpackungen GmbH & Co. KG
Julia Gruber
Phone: +49 (0) 7352 925-1358
E-Mail: Julia.Gruber@suedpack.com

Commha Consulting GmbH & Co. KG
Thorsten Diehl
Phone: +49 (0) 6221 18779 14
E-Mail: suedpack@commhaconsulting.com

Zott
Michaela Matthäus
Phone: +49 9078 801 106
E-Mail: michaela.matthaeus@zott.de

Receive the latest press information from BASF on your smartphone or tablet via WhatsApp. Register for our news service at https://www.basf.com/en/company/news-and-media/services/whatsapp-news.html.

Photo: Innovative and sustainable multilayer packaging used for a specially sealed mozzarella packaging for ZOTT Gourmet Dairy

© Zott

Downloads
Multilayer packaging: innovative and sustainable English, German
Photo: Innovative and sustainable multilayer packaging used for a specially sealed mozzarella packaging for ZOTT Gourmet Dairy © Zott
Media Contact
Virginia Wieser
Senior Manager, Corporate Communications, Brand & Reputation
+43 1 22 400 772
media@borealisgroup.com

Latest News

Media Release – 06/10/2022

Borealis and Bockatech showcase next-generation plastic foaming technology for more sustainable yet cost-saving thin wall and reusable packaging

Read more

Media Release – 04/10/2022

Borealis and VERBUND - Joint hydrogen project on an industrial scale

Read more

Media Release – 03/10/2022

Borealis restarts PDH construction site in Kallo with Ponticelli as contractor

Read more

Media Release – 20/09/2022

Borealis appoints Jonatas Melo as Vice President Performance Materials

Read more

Media Release – 15/09/2022

On presents the first ever shoe made from carbon emissions in partnership with LanzaTech, Borealis and Technip Energies

Read more

News – 18/08/2022

Borealis to retender the majority of contracts for PDH construction site in Kallo, Belgium, after termination of all contracts with IREM

Read more

News – 04/08/2022

Borealis suspends construction in Kallo after serious allegations against contractor and continues to support Belgian authorities in investigation

Read more

News – 01/08/2022

Borealis prolongs stand-still for its Propane Dehydrogenation (PDH) plant construction site in Kallo, Belgium

Read more

Media Release – 27/07/2022

Borealis suspends contract with IREM-Ponticelli and declares a three-day stand-still for its construction site in Kallo, Belgium

Read more