For packaging that cannot be reused, recycling is a critical solution enabling a circular value chain for materials. Consumers are increasingly aware of sustainability practices that focus on circularity, recycling and renewable sourcing. In response to growing consumer and regulatory concerns, major brand owners and large retail chains have announced sustainable packaging goals.
However, recyclability depends on the compatibility of the packaging materials ─ the packaging cannot contain any substances or combinations of materials that prevent successful recycling. In this interview, Didier Houssier, Global Market Development Director for Kuraray, shares insight into the recyclability of EVAL™, the company’s ethylene vinyl alcohol (EVOH) copolymer often used in packaging material.
Question: What is EVOH and how is it used in packaging?
Didier: Ethylene vinyl alcohol (EVOH) is a thermoplastic material widely used in the food packaging industry. In 1972, Kuraray was the first company in the world to produce EVOH and marketed it under the name EVAL™. Superior to other conventional copolymers, EVAL™ EVOH is recyclable, providing excellent barrier properties against the permeation of gases, such as oxygen, which can easily penetrate through the package and spoil the contents. It also helps contain the gases used in MAP packaging, including carbon-dioxide and nitrogen, that discourage spoilage. In multilayer structures, the properties of the different layers determine the barrier properties of the overall structure.
Kuraray‘s EVAL™ EVOH is combined with a wide range of materials, such as polypropylene (PP), to produce multilayer trays, pots or capsules that prevent gas or flavor permeation, as well as protect against external contaminants like mineral oils. Such trays are used in food packaging for a wide variety of products including coffee, ready-made meals, sauces, and fruit salads.
Question: How does EVOH fit into the circular economy model?
Didier: Kuraray supports the circular economy concept, a production and consumption model which involves the recycling of materials and products for as long as possible. We have performed thorough investigations on whether multilayer EVOH packaging material, which is a percentage of the post-consumer recycling (PCR) stream, can be effectively sorted within the polyolefin recycling streams, decontaminated and approved for use in PCR-based food packaging. Based on the levels of multilayer EVOH packaging typically found in the polyolefin recycling stream, our studies revealed the recycled polyolefins can be processed and utilized in a full range of applications without impact on migration characteristics or physical properties compared to recycled polyolefins alone.
Question: How do brand owners ensure their packaging containing EVOH is truly recyclable?
Didier: In Europe, guidance is given by recycling organizations such Ceflex and RecyClass, as well as many regional organizations. The recycling guidelines issued by those give positive recyclability assessments of EVOH in the polyolefins recycling streams.
In the U.S., the Association of Plastic Recyclers (APR) and the Sustainable Packaging Coalition provide the standard recycling guidelines, and when they confirm the recyclability of EVOH, the customer assessment is positive. These guidelines are updated regularly to reflect the latest findings.
Knowledge about functional barriers and their impact on the recyclability of plastic packaging is continuously expanding. We are thrilled by RecyClass’s July 2023 findings, which show that EVOH is additionally recyclable in polystyrene (PS) packaging, a type of plastic.
The RecyClass Polystyrene Technical Committee investigated the effect of EVOH used in polystyrene (PS) packaging. It concluded that EVOH up to 5 wt.% (in the presence of polyethylene (PE) layered with maleic anhydride (MAH) with a ratio of EVOH/tie layer equal or less than 1) will not disturb the recycling process of natural, white or colored PS. Therefore, RecyClass updated its Design for Recycling Guidelines to clearly communicate this full recycling capability. For EVOH over 5 wt.% and under the same conditions, there is still compatibility, but to a lesser degree.
Question: How does Kuraray support brand owners to meet these thresholds?
Didier: With EVAL™ EVOH, customers have full freedom to design functional packaging for their products. The key is to let each component of the structure do what it does best, using appropriate layer thickness. By combining different materials effectively, the total amount of packaging materials required may actually decrease. Grades of EVAL™ EVOH with lower ethylene content provide an ultra-high barrier and therefore can be applied in smaller thicknesses while still achieving a very effective oxygen barrier. With EVAL™ EVOH, almost any form is possible ─ cup, pouch, bottle, jar, bag-in-box… the possibilities are endless. Our technical experts help customers develop the optimum structure for their barrier packaging needs.
Question: There is continued and even increasing demand for EVOH in the packaging industry. How does Kuraray meet this challenge?
Didier: Kuraray made a commitment to strengthen its global supply system to address the increasing EVOH demand as part of PASSION 2026, our five-year, mid-term management plan. This plan outlines the clear steps Kuraray is taking in order to provide eco-friendly solutions that contribute to a more sustainable future. As such, we have recently announced increased production capacity in Europe and the United States, and we have plans to build a new EVAL™ EVOH plant in Asia. EVAL™ will continue to focus on developing high-performance barrier coatings and layers that help extend the shelf life of packaged goods, reduce food waste, and minimize environmental impact.
Question: What is the main message you’d like to share with readers?
In the dynamic realm of paper and packaging, Kuraray’s unwavering commitment lies in crafting solutions that transcend conventional boundaries. Our hope is that potential partners will bring their unmet needs to us, and as we identify and address those needs, we can catalyze positive change in the industry through reduction of food waste and environmentally conscious practices. We are resolute in our mission to shape a more sustainable future, and together, this is possible.