The European Aluminium Foil Association (EAFA), together with partner associations (European Aluminium, Aluminium Closures Group, Metal Packaging Europe, etma and AEROBAL) involved in aluminium packaging, has published a new framework for packaging design: the Design for Recyclability Guidelines and Recyclability Assessment for Packaging containing Aluminium. The aim is to ensure that packaging design facilitates efficient recycling at the end of the life cycle.

The guidelines are addressed first to packaging designers, but also to legislators and technical experts involved in the discussions on establishing appropriate methodologies for assessing packaging recyclability. The EU Packaging and Packaging Waste Regulation (PPWR) requires that by 2030 all packaging placed on the European market must be recyclable.

In this context, the Design for Recyclability Guidelines and Recyclability Assessment for Packaging containing Aluminium provide a scientifically sound approach for evaluating the recyclability of packaging predominantly made of aluminium. Furthermore, these guidelines render relevant information on the recyclability of packaging which contain aluminium as a minor material share.

“The PPWR sets ambitious objectives on packaging recyclability – we want to help ensure that the related provisions are implemented on a reliable and practice-oriented basis. Our guidelines provide a comprehensive overview and understanding of the factors having an impact on the recyclability of packaging containing aluminium, creating transparency for designers, regulators and the recycling industry,” stresses Jean-Paul Duquet, Director Sustainability at EAFA.

Technical background

Aluminium as a packaging material is characterised by properties that make it suitable for a wide range of applications. These include formats made predominantly of aluminium – such as semi-rigid foil containers, pet food trays, coffee capsules, alu/alu blister packs or foils for chocolate and cheese. They also include formats where aluminium is present in smaller shares but adds crucial functional properties – for example, aluminium as an essential barrier layer in pouches or beverage cartons.

Aluminium as a material is generally regarded as highly recyclable. However, when it comes to the recyclability of aluminium-containing packaging, there is room for improvement, and enhancement in both packaging design and recycling infrastructure can help.

As a benchmark, the guidelines apply state-of-the-art collection, sorting, reprocessing and recycling infrastructure, which has reached the highest Technology Readiness Level (TRL 9) and is available in Europe.

They have been developed in close alignment with the current provisions and terminology of the PPWR.

Practical recommendations for different packaging formats

Concrete design recommendations are included for a range of selected aluminium packaging formats in order to help designers improve their packaging recyclability.

“With the Design for Recyclability Guidelines and Recyclability Assessment for Packaging containing Aluminium, we have developed a practical tool that supports all stakeholders along the value chain – from packaging designers and brand owners to policymakers. This will help ensure that aluminium packaging is even better integrated into the circular economy in the future,” explains Sandra Beckamp, Managing Director at Institut cyclos-HTP, who acted as project manager.

With these new guidelines, the aluminium packaging industry is making an important contribution to a European circular economy. They provide orientation for all stakeholders and support the shared goal of designing packaging that is not only recyclable but also resource-efficient and functional. This achievement has been made possible through the close cooperation of numerous associations and experts along the entire value chain – a clear signal that the industry is ready to tackle the PPWR requirements jointly and constructively.

The Design for Recyclability Guidelines and Recyclability Assessment for Packaging containing Aluminium are now available for download at D4R.alufoil.org.

South Korea’s Ministry of Environment has recognised the recyclability of Ecolean’s aseptic packages, which rank higher than most other food and drink packaging solutions in the country’s new recyclability grading system.

The absence of aluminium, which is often used for aseptic cartons and other liquid food packaging, means Ecolean’s portfolio ranked ‘good’ in a four-grade scale to determine how easily packages can be recycled.

The announcement follows South Korea’s introduction last December of the Act on the Promotion of Saving and Recycling of Resources, requiring food and beverage packaging to contain labels that show a material’s recyclability grade, thereby encouraging resource efficiency and the use of easy-to-recycle packages.

A nine-month grace period for businesses to comply with the new regulations ends this September.

“The South Korean Ministry of Environment’s grade of the Ecolean packages’ recyclability only confirms that we are on the right path – developing and manufacturing unique packaging solutions that make a difference in the long run,” said Paul Mellbin, Senior Advisor, Ambient Technology at Ecolean.

“As a global producer of lightweight packaging, Ecolean makes it easier for consumers, liquid food brands as well as the environment.”

Aluminium-free packaging

Ecolean’s lightweight portfolio consists of aseptic, flexible packaging made from polyolefins and up to 35 % chalk, which gives the packages their strength, stiffness and smooth surface.

The printed, shaped and fully sealed packages are sterilised using electron beam treatment before shipping to the filling machine at the customer’s site. Prior to opening, filling and sealing in the filling machines, the outer surfaces of the packages are desterilised using a system of 1 % peroxide spray and UV light.

“The fact that our type of sterilisation process is separated from the filling machines and performed at the Ecolean manufacturing plants is quite unique in the industry and something we are very proud of. It makes the process easier for our customers, and that as well as having sustainability in mind when designing our lightweight packaging solutions is key. The confirmed recyclability of our packages in Korea just further adds to the fact that our unique approach is crucial for the beverage, dairy and liquid food industry” Paul Mellbin said.

Ecolean increased its footprint in South Korea last year with Yakult selecting its Air Aseptic range for two new launches in the country.

“The Ecolean package is the perfect fit for us, since it is lightweight and flexible, yet extremely durable. We have already seen a huge interest from consumers,” Jeonghyeon Hong, Marketing Manager, Yakult Korea, said.