Plastic packaging recycling tech

Triumphant Leap for Circular Plastics

A ground-breaking development in sustainable materials has gained significant industry recognition, marking a crucial step forward for global waste reduction. Nextek and Coveris have officially won the prestigious Packaging Recycling Project of the Year at the 2026 UK Packaging Awards. Held in London, the ceremony celebrated their joint breakthrough technology, COtooCLEAN, which overcomes decades of technical hurdles in recycling post-consumer flexible plastic packaging into food-contact applications.

Flexible films—such as bread bags, snack wrappers, and soft food pouches—have long presented a major challenge for municipal waste infrastructure worldwide. Because these materials absorb oils, inks, adhesives, and organic odors during their initial lifespan, conventional mechanical washing systems struggle to clean them thoroughly enough to meet stringent food safety standards. The recognition of COtooCLEAN underscores a shift toward scalable technology capable of closing the loop on soft plastic waste.  plastic packaging recycling tech

The Science Behind Waterless Purification

At the heart of this innovation is supercritical carbon dioxide ($\text{CO}_2$) purification. When carbon dioxide is brought to a specific temperature and pressure, it enters a supercritical state where it exhibits the density of a liquid alongside the penetrating flow of a gas. This unique thermodynamic property allows the fluid to penetrate deep into the polymer matrix of flexible plastic packaging without damaging the structural integrity of the polyolefin material. plastic packaging recycling tech

Unlike traditional mechanical recycling—which relies on water-intensive washing processes—this supercritical fluid process acts as a waterless solvent extraction mechanism. It effectively extracts embedded contaminants, volatile organic compounds (VOCs), residual oils, and unpleasant odors from post-consumer flexible packaging. Furthermore, by incorporating environmentally preferable co-solvents into the system, the technology target-cleans complex multi-layer films, printing inks, and adhesive residues.

This advanced purification step complements existing mechanical recycling lines rather than replacing them. By introducing a specialized decontamination phase, recyclers can upgrade low-value post-consumer film waste into high-purity recycled polyethylene (rPE) and polypropylene (rPP) resins that meet the safety and organoleptic requirements needed for direct food-contact packaging.

From Laboratory Innovation to Industrial Demonstration

The journey from proof-of-concept testing to commercial realization requires rigorous real-world testing. The central reason behind the UK Packaging Award win was the successful transition of COtooCLEAN from lab experiments to a fully operational demonstration plant at Coveris’ manufacturing site in Louth, Lincolnshire.  plastic packaging recycling tech

The path to industrial implementation has been supported by notable international recognition and funding:

• 2022 Alliance Prize: The technology secured the US$3 million Alliance Prize in Circular Solutions for Flexibles awarded by the Alliance to End Plastic Waste, providing financial momentum to scale operations.

• 2023 Materials Recognition: The project received the Institute of Materials, Minerals and Mining’s Circular Economy Award for its scientific approach to plastic decontamination.

• 2026 Operational Milestone: The demonstration facility in Louth became operational in April 2026, running continuous industrial-scale trials to gather critical operational data.

• 2026 Industry Accolades: Beyond winning at the UK Packaging Awards, the technology was named among the British Plastics Federation’s Top 15 Plastic Innovations of 2026.

The active demonstration facility in Lincolnshire generates key empirical data required to secure European food-contact regulatory approvals. This continuous data collection confirms the process’s viability, repeatability, and safety across varied post-consumer waste feeds.  plastic packaging recycling tech

Strategic Leadership and Industry Perspectives

Key figures behind the partnership highlighted the necessity of cross-sector collaboration to turn laboratory science into viable commercial applications.

Edward Kosior, founder and CEO of Nextek, noted that flexible film remains one of the most stubborn waste streams to process back into food-grade materials. He expressed appreciation for the operational support provided by Coveris and funding from the Alliance to End Plastic Waste, emphasizing that industry recognition validates the years of research required to bring supercritical $\text{CO}_2$ cleaning out of the lab.  plastic packaging recycling tech

Christian Kolarik, CEO of Coveris, highlighted that practical circularity requires hands-on industry trial environments. By hosting and running the demonstration plant, Coveris has helped bridge the gap between initial chemical design and large-scale manufacturing realities.

This technological step aligns with broader international legislative shifts. For instance, Extended Producer Responsibility (EPR) regulations are expanding across North America and Europe to shift municipal waste management obligations toward product manufacturers. Regions transitioning to producer-funded recycling networks—such as Alberta, Canada completing its paper and packaging EPR transition—are increasing pressure on package designers to utilize verifiably circular materials. Simultaneously, initiatives like the United Kingdom’s Simpler Recycling framework mandate kerbside collection of soft plastics, ensuring a steady stream of feedstocks for advanced purification infrastructure.  plastic packaging recycling tech

Global Lessons for Plastic Circularity

The achievements of the COtooCLEAN project offer practical guidance for countries struggling with flexible plastic waste. In nations such as Australia, where waste management infrastructure faces policy and market constraints, adopting advanced purification technologies can unlock substantial economic and environmental value.

As an advocate for circular plastics infrastructure, Kosior has consistently emphasized that technological advancements must be paired with supportive regulatory frameworks. Without clear policy mandates, stable end markets for recycled resins, and structured financial incentives, advanced recycling plants struggle to achieve commercial viability. The successful partnership between Nextek and Coveris shows how research entities, packaging producers, and non-profit organizations can pool resources to reduce risk and accelerate industrial adoption. plastic packaging recycling tech

The Road to Full Commercial Adoption

While winning the 2026 UK Packaging Award marks a celebrated milestone, the primary focus for Nextek and Coveris remains the final push toward commercialization. The primary steps ahead include:

1. Securing European Food-Contact Approvals: Completing toxicological challenge tests and submitting operational data to European regulatory bodies to verify non-intentional added substances (NIAS) are thoroughly removed.

2. Scaling Processing Throughput: Optimizing cycle times within the supercritical $\text{CO}_2$ pressure vessels to maximize output efficiency and lower operational costs per ton.

3. Integrating with Existing Recycling Facilities: Demonstrating that the modular decontamination process can be retrofitted or integrated into standard mechanical recycling facilities worldwide.

By addressing the underlying contamination bottleneck that has historically relegated soft plastics to low-grade downcycling or landfilling, this advanced purification technology lays the foundation for true closed-loop flexible packaging. As regulatory standards tighten worldwide, scaling these innovations will prove vital for building a cleaner, resource-efficient circular economy. plastic packaging recycling tech

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