다층 포장 재활용: 혁신과 도전 과제

### 다층 포장 재활용의 도전 과제 해결
* 🥔 인류는 매년 **600만 톤 이상의 감자칩**을 생산하며, 주로 재활용하기 어려운 복잡한 다층 봉투에 포장되어 있습니다.
* ♻ 금융업계를 떠난 아니쉬 말파니는 **2021년부터 30만 개의 칩 백을 선글라스로 성공적으로 재활용**하는 스타트업을 설립하여 시급한 MLP 폐기물 문제를 해결하고 있습니다.
* 📦 종이 봉투에서 최신 다층 패키지로 칩 패키징이 진화하면서 **유통기한이 크게 연장**되었지만, 이러한 재료가 매립되는 경우가 많아 환경 문제가 심각해졌습니다.
* 🔬 Anish의 팀은 이러한 까다로운 재료를 재활용하기 위해 제조 기계를 개조하여 **처리 속도를 시간당 1킬로에서 10킬로까지 향상**시켰습니다.
* 지텐드라 삼다니 박사는 광범위한 실험 끝에 **MLP에서 일반적인 플라스틱을 분리하는 방법**을 개발하여 이러한 물질을 사용 가능한 형태로 재활용할 수 있게 되었습니다.
* 🌍 혁신적인 노력에도 불구하고 MLP의 재활용은 여전히 제한적이며, **상업적 규모로 이 문제를 성공적으로 해결한 파일럿 프로젝트는 소수**에 불과합니다.
* 💔 다층 포장의 글로벌 시장은 **2023년까지 2,500억 달러를 넘어설 것**으로 예상되는 등 빠르게 확대되고 있으며, EU는 **2030년까지 모든 식품 포장재를 재활용 또는 재사용**할 수 있도록 하는 것을 목표로 하고 있습니다.
* 🔄 아니쉬는 재활용 관행에 대한 체계적인 변화의 필요성을 강조하며 **"저는 실질적이고 체계적이며 영구적인 변화를 원합니다."**라고 말하며 환경 문제 해결을 위한 장기적인 노력의 중요성을 강조했습니다.

아니쉬 말파니는 재활용이 불가능한 칩 백을 선글라스로 변신시켜 혁신적인 재활용 방법으로 주요 환경 문제를 해결합니다.

Narrator: Humans make more than 6 million metric tons of potato chips each year. And most of them come in bags like this. They're typically made of multiple microlayers of plastics and aluminum, each serving a different purpose, and they're engineered to keep snacks fresh and crisp for six months or longer. But this sophisticated design, used in everything from yogurt pouches to juice boxes, has created a major environmental problem since the material almost always ends up in landfills. It's considered, quote, unquote, impossible to recycle. Narrator: Anish Malpani quit his finance job and dedicated his life to solving this problem. Since 2021, his startup has recycled 300,000 chip bags into sunglasses. But why are these packages so difficult to recycle? And are big manufacturers doing anything to fix the problem? In the early 1900s, chips were often sold from open barrels and glass jars.

and packed into paper bags, where they stayed fresh for only a day. Over the following decades, companies packaged them in things like waxed or glassine paper or tin cans to boost shelf life. In the 1950s, manufacturers began selling their chips in cellophane and paper bags lined with aluminum foil, extending their shelf life by several weeks. They offered better resistance to moisture and light, but they didn't have an airtight seal. In the 1970s, a revolutionary process called coextrusion allowed manufacturers to layer several types of plastic into a single film, creating the first generation of multilayered packaging. By the 1980s, many foods were being sold in three layers of packaging. Today, some of these multilayer packages, or MLPs, can have as many as 11 layers. The middle of a modern chip bag is usually made from plastic resistant to oil, grease, and moisture.

But this doesn't fully block oxygen or light, so it's often coated with aluminum to form the innermost layer. The bag's outer layers must be strong, flexible, and printable. So they're made with two plastics. The undercoat has the graphics. The outermost layer protects them. Before a bag is sealed, it's filled with nitrogen gas to create a low-oxygen, low-moisture atmosphere. Together, this design helps chips stay fresh and crisp for six months. And this deceptively simple-looking design is everywhere. In 2023, the world produced enough MLPs to fill about 4 million garbage trucks. And most recycling facilities don't have the technology to separate or process these packages. So they are usually sent to landfills or incinerators. Anish: MLP is the black sheep of the plastic family. Nobody wants this material. Narrator: That includes most waste pickers, who normally can't sell this ubiquitous kind of trash.

Lubna: So finding a solution for this, where they can be compensated fairly, is of utmost importance to the waste pickers. Narrator: Lubna Anantakrishnan works for SWaCH, a cooperative of waste collectors that only started gathering MLPs after a giant manufacturer started paying for it. Now, Anish buys 100 kilograms of thin plastic wrapping from SWaCH every month. Without's headquarters is just one of a handful of places in the world that can recycle MLPs. Because we were approaching this from a problem-first perspective, we chose the things that nobody wants to work on. In the beginning, many people thought we were idiots, like, you know, what are you doing? This doesn't make any sense. Narrator: Anish and his team spent a lot of time buying and modifying common manufacturing machines like shredders and extruders to recycle these packages. Anish: It's not like all of them are designed by us.

or all of them are off the shelf. It's a combination. It's like a jigsaw puzzle where you're kind of finding this piece and making it. Narrator: First off is a modified shredder. It's equipped with a special vacuum that pulls the lightweight films through so it doesn't clog. Anish: MLP or chips packets are very light, so it's very hard to sometimes shred them. You need, like, extra force to suck the materials that actually gets shredded properly. In the first shredder, we could do only about 1 kilo an hour maybe. Now we do 10 kilos an hour. Narrator: Workers wash the flakes to remove any glue or dirt. Then they skim them and transfer them to drying racks. A technician weighs the dried flakes before loading them into the company's real innovation, a custom-built 100-liter reactor that reaches about 250 degrees and actually separates the layers. It took two years to figure out the right process.

Anish doesn't have a science background, so when he started Without, he placed an ad online, looking for someone to help him build machines that recycled the unrecyclable. I was like, hey, I'm looking for a scientist to help me tackle this. Narrator: That's how he found Dr. Jitendra Samdani. Jitendra's main challenge was to discover how to separate the mix of commonly-used plastics that make MLPs. That's why people don't go towards the MLP recycling. It's not a simple kind of ways. Narrator: He tried over 1,000 experiments until he figured out the right reaction that would isolate three of the most common types of plastics, polypropylene, polyethylene, and PET. That's the moment, we say the wow moment, for us. Narrator: Jitendra built the reactor to standardize and scale his new process.

It uses water with a high pH to cause a reaction that partially separates the layers. The reaction dissolves the aluminum and breaks the PET plastic into its basic molecular structure. And what we get is a bunch of building blocks. Narrator: Anish's current R&D lab can separate about 8 kilograms of material a day, but he wants to get closer to 100 kilograms before he opens a larger plant. And we're still working on improving the rate of the reaction because we need to make sure that we can do it in the most efficient way possible. Narrator: The reaction leaves behind a mix of plastics, some of which can't be used to make Without sunglasses. Eventually, Anish wants to make bricks with them, but for now, they're just stored on-site. To get the needed PET plastic, workers wash the mix with sulfuric acid. Then they load the flakes into a barrelful of water.

and connects two hoses to something called a hydrocyclone. It's typically found in agriculture, and it uses centrifugal force to separate sand and mud from water. Here, that force separates the lighter plastics, like polypropylene and polyethylene, from the heavier plastics, like PVC and nylon. The material is continuously run through both the barrel and hydrocyclone for 45 minutes until the only thing left are the lighter plastics, which get skimmed off the top. The plastics are dried overnight at 60 degrees Celsius. In the morning, workers remove the flakes and run them through a machine that compacts them into a more solid form. Workers then load it into a mixing machine and sprinkle some of the naturally green materials with a fine, black carbon-based powder. Anish: Our material is not transparent. It's either green, gray, or black. Narrator: A technician pours the flakes into a customized twin-screw extruder that mixes, melts,

and pushes out the plastic as a filament. Anish: We don't add any virgin plastic, but we do add additives and compatibilizers to give it the energy and the life that it requires. Narrator: These additives include widely used chemicals which improve the plastic's overall quality and durability. The filament leaves the extruder at 200 degrees Celsius, and it's cooled rapidly with water tanks. Another machine cuts the filament into pellets. Recycled plastic often starts in pellet form before it's shaped into a final product, and it took over two years for Anish to figure out what his would be. So we brainstormed over 400 different products. We short-listed 70. Then in the 70, we looked at 27 different parameters based on team excitement, complexity, average Amazon searches, and margins, and all of that. And then sunglasses scored very highly on that. Narrator: The pellets are melted

and injected into molds for frames and hinges. Anish estimates that a single pair of glasses takes about five packets of chips. A robotic arm stamps the hinges with a logo and a QR code so buyers know where and when their frames were made. Workers assemble each pair by hand-cutting plastic lenses imported from China and screwing frames together. Anish: So we can make between 500 to 1,000 sunglasses a month. Narrator: All told, the company has recycled 1,500 kilograms of MLPs. That's, like, close to 300,000 packets of chips. It sounds big, but it's not a lot. We're like a drop in the ocean. Narrator: For now, Without only sells them online in India for $10 apiece. But Anish hopes to expand the product to the US, Europe, Australia, and New Zealand. Anish's process is complicated, but it only took a small team to figure it out.

So why isn't everyone doing this? Most plastic recyclers are designed to handle one kind, such as PET, PVC, or HDPE. Processing mixed plastics would require retrofitting old equipment or developing new machines that could detect and separate them. Because separation almost never happens, there's no market for the mixed materials Anish is working with. Recycling them profitably is practically impossible. We looked around, and outside about a half a dozen pilot projects, MLPs are almost never recycled at a commercial scale. One of those projects is at the University of Wisconsin-Madison, where Professor George Huber and his team spent six years developing a way to process MLPs using solvent washes. They call it STRAP, short for Solvent Targeted Recovery And Precipitation. So this is a film we made when we pulled out the polyethylene from this, and we went back, we made the powder, we made the pellets,

and then we went to remake the film. Narrator: The STRAP team is building a pilot plant that can process about 25 kilograms of MLPs an hour. But they'll need to recycle at least 20 times that to be profitable. George: And then you go larger than that, 1,000 kilograms per hour, you're looking really good. Narrator: That kind of scale takes huge resources. Indeed, a lot of MLP recycling is only possible with corporate subsidies. Remember how SWaCH started collecting MLPs? It's because a giant food supplier that makes them, called ITC, sponsors the program. Lubna: If you'd only look at the costs of buying it from a waste picker, aggregating and sorting it, and then getting it to a recycler, the value generated from MLP today is not really enough for this to be viable. Narrator: Other companies have also struggled to tackle MLP waste,

partly because the packaging is so popular with consumers. In 2010, SunChips released a compostable chip bag made from PLA, a biodegradable plastic sourced from cornstarch. While it was actually compostable, in a compost pile larger than 21 cubic feet, customers complained about how loud it was. The only problem? It sounds like a hailstorm. Narrator: SunChips' sales declined, and the company stopped making the bags 18 months after their release. In 2022, Frito-Lay reintroduced a compostable bag for its brand Off the Eaten Path. It was quieter but could only be broken down using an industrial composter, not the one in your backyard. That same year, one of the world's biggest MLP manufacturers, the Swiss company Tetra Pak, started working with schools in Thailand to recycle milk cartons into various building materials. This school goes through about 5,000 containers a month,

and nearly all of them get recycled. Narrator: The recycling program is active in over 400 Bangkok schools, as well as more than 150 drop-off points across the capital. The cartons end up here at Eco Friendly Thai, a recycling company that specializes in beverage containers and used paper. The Ratchaburi plant processes about 12 million cartons a month. First, they have to be broken down to make it easier to separate the cardboard from the plastic and aluminum. The walls of the cartons made by Tetra Pak have six layers. All of them can be recycled on their own, but many recycling facilities don't have machines that can process them all at once. About 70% of the carton is paper, which provides structure. Polyethylene plastic makes up 20% and helps seal the packaging. The last 5% is aluminum. A thin foil helps keep the contents fresh and extends the product's shelf life. And a special heating process

sterilizes both the product and the package, making some items shelf-stable for up to a year. The hydrapulper breaks up the layers into tiny pieces. Then the boxes go through three filters to separate and remove the paper. Each filter is finer than the last. Any wastewater gets pumped back into the pulper. Narrator: The remaining plastic and aluminum end up here, at the dump screen. Those will get turned into building materials, like bricks and roofing sheets. The pulp is trucked to another plant and will be turned into toilet paper and cardboard. But this is a fraction of Tetra Pak's overall output. The company says it reclaimed 390 million containers in 2023, just 7% of the cartons sold in Thailand alone. While new technologies promise to make recycling more efficient, it's unlikely we'll be able to recycle our way out of this problem. The global market for multi-layer packaging is growing.

And it's overtaking other types of food packaging. By 2023, the market is projected to be worth more than $250 billion. The EU wants all food wrapping to be recyclable or reusable by 2030. But that will be very, very hard if facilities can't identify, sort, and recycle multilayer packaging. Lubna: We need the people making MLP, the producers making MLP, to be genuinely responsible for the material they are putting in and realistically for the solutions for MLP to be able to work at the scale of the problem. Narrator: Some brands are returning to monolayer plastic films, like these ones made by a company called Toppan. But they aren't perfect. George: We don't really recycle films very well at all right now. And so no one is really buying these monolayer materials. Narrator: For now, Anish plans to continue refining his process, trying to make it work on an industrial scale.

And I'm not trying to look for a quick hack. I'm looking for a real, systemic, permanent change. And that takes time. And that requires commitment. And that's when the real work, the real impact starts coming in.

Why Are Chip Bags So Hard To Recycle? | World Wide Waste | Business Insider

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감자칩 봉투가 환경에 미치는 영향

여러 겹의 미세 플라스틱과 알루미늄으로 만들어진 감자칩 봉투는 과자를 6개월 동안 신선하게 보관할 수 있도록 설계되었지만, 결국 매립되어 심각한 환경 문제를 야기합니다.

아니쉬 말파니의 스타트업은 2021년부터 30만 개의 칩 백을 선글라스로 재활용하여 이러한 포장재 재활용의 어려움을 강조하고 있습니다.

다층 포장의 생산은 수십 년 동안 급증하여 최신 칩 백은 최대 11겹으로 구성되어 있지만 대부분의 재활용 시설에는 이를 처리할 기술이 부족하여 매립지나 소각로에서 폐기되고 있습니다.

다층 플라스틱의 혁신적인 재활용

SWaCH의 루브나 아난타크리슈난은 한 제조업체가 다층 플라스틱(MLP)에 대한 비용을 지불하기 시작한 후 이를 수거하는 데 중요한 역할을 해왔습니다.

Without의 아니쉬 팀은 일반 제조 기계를 개조하여 MLP를 재활용함으로써 시간당 파쇄 용량을 1킬로그램에서 10킬로그램으로 늘리는 데 성공했습니다.

지텐드라 삼다니 박사는 1,000번의 실험을 통해 MLP에서 가장 흔한 세 가지 유형의 플라스틱을 성공적으로 분리하여 재활용 공정을 표준화하고 규모화하는 데 성공했습니다.

Anish의 혁신적인 플라스틱 재활용 프로세스

Anish의 연구실에서는 높은 pH의 물을 사용하여 알루미늄과 PET 플라스틱을 분리하여 하루에 처리량을 8킬로그램에서 100킬로그램으로 늘리는 것을 목표로 하고 있습니다.

재활용 공정에는 황산으로 플라스틱을 세척하고 하이드로사이클론을 사용하여 분리한 후 압축하기 전에 재료를 건조하는 과정이 포함됩니다.

펠릿 형태의 최종 제품은 트윈 스크류 압출기를 통해 만들어지며 선글라스를 비롯한 다양한 품목을 생산하는 데 사용됩니다.

혼합 플라스틱 폐기물의 혁신적인 재활용

Anish의 회사는 성형, 스탬핑, 수작업 조립 등 복잡한 공정을 통해 칩 패킷의 다층 플라스틱(MLP)을 재활용하여 선글라스를 만듭니다.

1,500kg의 MLP를 재활용하지만 그 영향은 미미하며, 혼합 플라스틱을 다루기 어렵기 때문에 공정이 까다롭습니다.

위스콘신-매디슨 대학교의 STRAP 프로젝트도 MLP 재활용을 위해 노력하고 있지만 대규모로 수익성을 달성하려면 상당한 자원과 기업 보조금이 필요합니다.

2010년에 출시된 선칩스의 퇴비화 칩 봉투는 인기가 있었지만 시끄러워 판매량이 감소하고 단종되었습니다.

프리토레이는 2022년에 산업 퇴비화에만 적합한 더 조용한 퇴비화 봉투를 재도입했습니다.

태국 테트라팩의 재활용 프로그램은 우유팩 재활용에 성공했지만, 전체 생산량은 여전히 미미하여 다층 포장에 대한 과제가 점점 더 커짐에 따라 어려움을 겪고 있습니다.

식품 포장재 시장은 2023년까지 2,500억 달러를 넘어설 것으로 예상되며, EU는 2030년까지 모든 식품 포장재를 재활용하거나 재사용할 수 있도록 하는 것을 목표로 하고 있습니다.

다층 포장은 재활용이 어렵기 때문에 일부 브랜드는 여전히 재활용에 어려움을 겪고 있는 단층 플라스틱 필름으로 돌아가고 있습니다.

Anish는 포장 솔루션의 체계적이고 영구적인 변화를 위해 프로세스를 개선하는 데 집중하고 있으며, 이를 위해서는 시간과 노력이 필요하다고 강조합니다.