DEBO-Pack: Debonding on demand for multi-material packaging

The aim of the Fraunhofer joint project "DEBO-Pack" is to develop recyclable multi-material packaging by separating the components by type using "debonding on demand." The DEBO-Pack approach significantly improves the recyclability of hybrid packaging such as plastic (cardboard) composite materials by allowing composite packaging to be separated autonomously after use. The focus is on seamlessly integrating the DEBO-Pack solution into established recycling processes without fundamentally changing or redesigning the existing recycling system. Fraunhofer UMSICHT contributes its comprehensive expertise in the areas of recycling technology, materials research, stakeholder involvement and consumer acceptance to this Fraunhofer joint project in order to develop a sustainable and marketable solution.

Challenges in packaging recycling

Compared to monomaterial approaches, hybrid packaging made of plastic and cardboard can significantly reduce the plastic content, but this usually impairs the recyclability of the packaging. These cannot be recycled efficiently with conventional recycling and sorting facilities. The market therefore offers packaging solutions that require consumers to actively separate the materials (e.g., yogurt cups with cardboard sleeves). In addition, consumers are uncertain about how to dispose of cardboard-plastic hybrid packaging, as they have to choose between the wastepaper bin and the yellow bin. As a result, the likelihood of incorrect disposal increases. The resulting contaminants in the recycling streams reduce the quality of the recycled material.

Ensuring recyclability under existing recycling structures

As part of the project, researchers are further developing multi-material packaging, testing recycling processes, investigating the influence of adhesive degradation products on recyclability, and adapting existing recycling processes where necessary. Taking technological recycling standards into account, they are evaluating the adaptation of processes to novel adhesives. This enables efficient material recycling of the separated packaging components in existing recycling structures and improves the quality of the recyclates. The effects of the debonding approach on recyclability are always taken into account in the development process to shorten and simplify the separation and recycling processes.

Creating a sustainable and marketable solution

Multimaterial packaging goes through various phases before it reaches consumers – from initial development to production and retail. The functionality of packaging must always be guaranteed, but design also plays an important role for end consumers. This is where decisions are made about which recycling options the packaging will be assigned to in the recycling process and how successful its actual recycling will be. The DEBO-Pack solution addresses this disposal behavior: Among other things, it provides protection against human error in the disposal process.

With a holistic view of the packaging system and recycling processes, this project is creating a sustainable and recyclable packaging solution that meets the requirements of the circular economy and, ideally, can be transferred to other areas of application. The research team has already developed initial demonstrators based on these requirements and investigated how they fit into existing structures. Surveys and studies in real-world environments will provide further insights into the potential and challenges of the new DEBO-Pack packaging solution.

At the end of the project period (2027), concrete recommendations for action will ensure the successful implementation of the cycle-optimized multi-material packaging. The recyclability of the individual components must always be ensured through "debonding on demand." For successful implementation on the market, the involvement of stakeholders along the value chain is just as important as consumer acceptance and compliance with regulatory requirements.

• Fraunhofer Institute for Manufacturing Technology and Applied Materials Research IFAM
• Fraunhofer Institute for Process Engineering and Packaging IVV
• Fraunhofer Institute for Building Physics IBP