A research team at Michigan State University has introduced a breakthrough solution that addresses one of the most persistent challenges in sustainable packaging: how to cost-effectively recycle multilayer plastics (MLPs). Backed by the U.S. Department of Energy and the REMADE Institute, this innovation could shift the conversation around waste, manufacturing, and sustainability across the U.S. packaging value chain.
Why This Matters
MLPs are used extensively in food packaging, valued for their strength, shelf life, and barrier performance. But they’re notoriously difficult to recycle, resulting in billions of pounds of plastic waste ending up in landfills or incinerators every year.
MSU’s innovation makes MLPs recyclable without requiring manufacturers to change equipment or processes. That’s the game-changer. It’s a drop-in adhesive layer that enables two recycling paths: traditional mechanical recycling and a new water-based separation method.
Solving the Scalability Problem
Unlike many sustainability tech solutions that stall in pilot due to high integration costs, this adhesive was designed with adoption in mind. No new machinery. No overhaul of production systems. Just better circular outcomes, built on existing infrastructure.
Projected Impact at Scale
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Divert 1.14 billion kg of plastic waste annually
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Cut emissions by 4 billion lbs CO₂
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Save energy equivalent to 457 million gallons of gasoline
Beyond emissions and landfill diversion, this solution supports national goals around domestic manufacturing, supply chain resilience, and reducing exposure to microplastics, a growing public health and regulatory concern.
What Businesses Should Watch Out For
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No CapEx barrier: Easy-to-integrate adhesive; no production changes needed
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Recyclability upside: Preserves material value, not just downcycled waste
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Market pressure: Aligns with growing B2B/B2C demand for traceable, circular packaging
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Strategic positioning: Supports ESG targets and federal sustainability mandates
If you’re evaluating sustainable materials innovation or seeking a commercially viable path to meet packaging recovery goals, this development deserves space on your radar.
