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MERLIN · Project

Turning Unrecyclable Multilayer Plastic Packaging Into Reusable Raw Materials

environmentTestedTRL 6
merlinproject.eu

Think of a chip bag or a juice pouch — they're made of multiple plastic layers glued together, which makes them nearly impossible to recycle. Right now, most of this stuff just gets burned or buried. MERLIN figured out how to peel those layers apart, sort the different plastics using AI-powered cameras and robots, and turn them back into usable materials. It's like learning to un-bake a cake so you can reuse the flour, eggs, and sugar separately.

By the numbers
17%
Share of total plastic packaging that is multilayer
3.03 Mt
Annual multilayer plastic packaging volume in Europe
7.42 Mt CO2/year
Potential annual carbon footprint saving from recycling all multilayer waste in Europe
€10,605 million
Potential economic value of multilayer packaging recycling in Europe
106,000
Potential new job positions from multilayer recycling
EUR 4,926,225
EU contribution to the project
19
Consortium partners across 7 countries
74%
Industry partner ratio in the consortium
The business problem

What needed solving

Europe produces 3.03 million tonnes of multilayer plastic packaging every year — chip bags, juice pouches, medical blister packs — and almost none of it gets recycled. The multiple plastic layers bonded together make it impossible for standard recycling plants to process, so it goes straight to landfill or incineration. Companies face tightening EU regulations demanding recyclable packaging by 2030, but have no proven technology to handle multilayer waste at scale.

The solution

What was built

MERLIN developed and validated a complete multilayer recycling chain: AI-powered optical sorting with robotics to identify and separate multilayer packaging, chemical delamination processes to peel apart bonded polymer layers (PET, PE, PP), and repolymerization techniques to turn recovered materials back into usable plastics. They also built a Decision Support System for packaging recycling and a QR code traceability system for circular packaging.

Audience

Who needs this

Plastic recycling plant operators looking to process multilayer waste they currently rejectFood and beverage packaging manufacturers needing to meet EU 2030 recyclability targetsWaste sorting equipment manufacturers wanting to handle multilayer fractionsRetail chains with sustainability commitments seeking recyclable packaging alternativesChemical companies producing adhesives and barrier layers for packaging
Business applications

Who can put this to work

Plastic recycling and waste management
mid-size
Target: Recycling plant operators processing mixed plastic waste

If you are a recycling company struggling with multilayer packaging that contaminates your output streams — this project developed AI-powered sorting combined with chemical delamination processes that separate PET, PE, and PP layers for clean recycling. With 17% of all plastic packaging being multilayer (3.03 Mt annually in Europe), this opens a waste stream you currently landfill or incinerate.

Food and beverage packaging
enterprise
Target: Packaging manufacturers producing multilayer flexible and rigid packaging

If you are a packaging manufacturer facing pressure to make your products recyclable by 2030 — this project validated cradle-to-cradle packaging designs using recycled multilayer materials at TRL 6 in real environments. The Decision Support System helps you choose material combinations that stay recyclable without sacrificing barrier performance.

Waste sorting technology
SME
Target: Equipment manufacturers building optical sorting and robotic systems

If you are a sorting technology provider looking to expand into hard-to-sort waste fractions — MERLIN combined optical sensors, AI, and robotics to identify and separate multilayer packaging that current NIR sorters miss. The consortium of 19 partners across 7 countries validated these systems, creating a proven technology stack you can integrate or license.

Frequently asked

Quick answers

What would it cost to implement this technology?

The project operated on a EUR 4.93 million EU budget across 19 partners over 36 months. Specific per-unit implementation costs are not published in the available data. Contact the consortium for pricing on individual technology modules (sorting, delamination, or repolymerization).

Can this work at industrial scale?

The technologies were validated in real environments targeting TRL 6, meaning they work outside the lab but are not yet full production-scale. With 14 industry partners and 10 SMEs in the consortium, the path to scale-up has strong industrial backing. Further engineering would be needed for full plant integration.

What about IP and licensing?

The project was funded as an RIA (Research and Innovation Action) with 19 partners. IP is shared among consortium members according to their grant agreement. Businesses interested in licensing specific technologies should contact the coordinator or relevant technology-owning partners directly.

Which plastic types does this handle?

MERLIN specifically targets PET, PE, and PP — the most common polymers in multilayer packaging. The sorting system uses AI and optical sensors to identify these materials, while delamination processes separate them for individual recycling streams.

What's the environmental impact?

Based on the project's own estimates, recycling all multilayer packaging waste in Europe could save 7.42 Mt CO2 per year. The potential economic value is estimated at EUR 10,605 million with over 106,000 new jobs. These are Europe-wide projections, not per-plant figures.

Is this compliant with upcoming EU packaging regulations?

The project directly addresses the European Plastics Strategy goal that by 2030 all plastic packaging should be recyclable or reusable. Transversal activities on regulation and standardization were part of the project scope. Based on available project data, specific regulatory certifications are not detailed in the public deliverables.

How long until this is market-ready?

The project closed in November 2024 having reached TRL 6. Moving to commercial deployment (TRL 8-9) typically requires 2-3 years of additional engineering and scale-up. The high industry ratio in the consortium (74%) suggests commercialization pathways are already being explored by partners.

Consortium

Who built it

MERLIN's consortium is unusually industry-heavy: 14 out of 19 partners are from industry (74%), with 10 being SMEs. This signals strong commercial intent — these aren't academics writing papers, they're companies building products. The consortium spans 7 countries (Belgium, Germany, Spain, France, Croatia, Italy, Netherlands), covering major European packaging and recycling markets. The coordinator is ITENE, a Spanish packaging technology institute that also qualifies as an SME, bridging research and business. With only 1 university and 3 research organizations, the balance clearly favors market-oriented development over pure science.

How to reach the team

ITENE (Instituto Tecnológico del Embalaje, Transporte y Logística) in Spain — a packaging technology institute. Use Google AI Search to find the project coordinator's direct contact.

Order a report on this consortiumSee INSTITUTO TECNOLOGICO DEL EMBALAJE, TRANSPORTE Y LOGISTICA profile →
Next steps

Talk to the team behind this work.

Want to connect with the MERLIN team about licensing their sorting, delamination, or recycling technology? SciTransfer can arrange a direct introduction — contact us for a matchmaking consultation.

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