Project R-16699

BaReFOOD: Functional Barrier strategies for Recycled polyethylene in FOOD packaging (Research)

The transition towards circular food packaging is accelerating under the Packaging and Packaging Waste Regulation (EU) 2025/40 (PPWR), which sets binding post-consumer recycled (PCR) content targets. From 2030, contact-sensitive plastic packaging other than PET is subject to a minimum recycled-content target of 10%, increasing to 25% by 2040. Achieving these targets while ensuring food safety remains particularly challenging for polyethylene (PE). Mechanically recycled PE is a promising short-term PCR source, but its use in food-contact packaging is limited by variable quality, potential contaminants from inks, adhesives, additives, degradation products and previous use, and their relatively high diffusivity through PE. Validated functional barrier strategies are therefore needed to enable the safe use of PE PCR under realistic application conditions. The CORNET project BaReFOOD aims to develop and validate recyclable, PE-based multilayer packaging structures enabling the safe incorporation of 10–25% PE PCR through functional barrier technologies. Pilot-scale flexible and rigid demonstrators containing at least 90% PE will be produced, supported by design guidelines, challenge-testing protocols, and scale-up documentation. The project follows a stepwise approach: First, controlled model systems based on virgin PE spiked with representative surrogate contaminants will be used to establish and validate barrier-performance requirements before transitioning to commercially relevant PE PCR feedstocks. Second, selected functional barrier strategies will be developed and implemented in flexible and rigid multilayer structures. The resulting structures will be assessed for migration, sealability, gas permeability and mechanical performance under realistic use and storage conditions. Finally, life cycle and techno-economic assessments will evaluate environmental impacts, industrial feasibility and scale-up potential of the most promising solutions. The findings will be integrated into representative case studies to support industrial implementation. BaReFOOD will create value across the packaging value chain by supporting the uptake of high-quality PE recyclate in food-contact applications and strengthening regional circular material flows. The generated scientific evidence will also contribute to regulatory and policy developments for safe circular packaging. Through uniting local SMEs, large enterprises, material producers, recyclers, extended producer responsibility (EPR) organizations, IVLV and research partners from UHasselt and Fraunhofer IVV and IGCV, the project will facilitate knowledge transfer, cross-sector innovation and industrial uptake of the developed solutions.

01 September 2026 - 31 August 2028