High-Barrier All-Polyolefin Multilayer Supporting PE-Stream Recycling and Water-Based EVOH/PO Separation 

 

Summary: 

PE-dominant multilayer architecture (90 wt%) incorporating water-dissolvable tie layers to enable mechanical recycling and hot-water separation into high-purity EVOH and polyolefin streams. 

 Layer architecture 

  • Structure: PO (print) / Water dissolvable tie layer / EVOH / Water dissolvable tie layer/ PO sealant 
  • Total gauge: 70 µm 
  • Composition (wt%): PO family 90%, EVOH 5%, water dissolvable tie layer 5% 

Barrier: 

  • OTR (ASTM D3985): <3 cc/m²/day @ 23°C / 50% RH 
  • WVTR (ASTM F1249): <0.25 g/m²/day @ 38°C / 90% RH  

Mechanical + converting:

  • Tensile (D882): 55 MPa
  • Elongation: >30% 

 Recycling compatibility: 

  • Target stream: PE film 
  • Density: 0.93 g/cm³ 
  • MFR: 1.2 g/10 min @ 190°C/2.16 kg 
  • Non-compatible fraction total: 8 wt% (EVOH + tie) 

EoL:

  • Mechanical recycling yield: 90% (wash + repelletize) 
  • Property retention after 1 cycle: ~90% 

Biggest Novelty – Dual Recycling Pathway:

In addition to mechanical recycling compatibility, this multilayer structure supports water-based separation into pure individual resin streams, enabling recovery of constituent materials for independent reprocessing. 

Material recovery yield: ≥ 70 % 

Polyolefin purity: ≥ 99% 

EVOH purity: ≥ 90% 

Property retention vs virgin: 100% 

Contact: 

rabnawaz@msu.edu 

Developed by: 

Sustainable Materials Group, Michigan State University (MSU) 

 

 

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