The truth about the recyclability of cross-linked films: between misleading marketing and industry reality
In the world of flexible packaging, there should be a convergence towards transparent and scientifically sound solutions, but we are witnessing a worrying proliferation of misleading statements about the recyclability of materials. It is time to shed light on one of the most controversial issues in the industry: are cross-linked films recyclable? And how to distinguish a cross-linked film from one that is not?
Recycling with pyrolysis: theory and practice
Those who claim that cross-linked films are recyclable refer to an existing technique called pyrolysis, which breaks them down into their basic components. But the economic and practical realities make this process unfeasible because pyrolysis requires extremely high temperatures, prohibitive energy consumption and investment in specialised plants that make the process economically unsustainable on an industrial scale.
The current situation speaks for itself: there are very few operational pyrolysis plants in the world, insufficient to process even a tiny fraction of the cross-linked materials produced annually. Yet many manufacturers continue to label these materials as “recyclable”, taking advantage of the terminological confusion and lack of information in the industry.
Damage of cross-linked films to conventional recycling processes
The issue becomes even more serious when we consider what actually happens when cross-linked films enter the conventional recycling stream. It is not only that these materials cannot be processed - their presence can literally cause conventional mechanical recycling plants to shut down and be damaged.
Due to the permanent chemical bonds created during the cross-linking process, cross-linked films do not melt like standard thermoplastic polymers. When they end up in the extrusion lines of recycling plants, they can create blockages, damage filters and nozzles, and contaminate entire batches of otherwise recyclable material.
Distinguishing between cross-linked and non-cross-linked films
A further element of complexity is the identification of cross-linked materials themselves. While in a laboratory, with appropriate equipment and specialised personnel, it is possible to distinguish a cross-linked film from a non-cross-linked one through specific tests (such as gel content analysis or solubility tests), this distinction is practically impossible in a waste sorting centre.
Recycling centre operators work at a fast pace and have neither the time nor the tools to perform chemical analyses on incoming materials. The result?Cross-linked and non-cross-linked films are inevitably mixed, compromising the entire recycling process.
Certification as a tool for transparency
At Decofilm, we have chosen the path of total transparency for several years now. Our products have been certified by Interseroh, a prestigious German body that does not simply state generically whether a material is “recyclable” or not, but assigns a recyclability score based on objective and verifiable criteria.
This step-by-step approach is crucial because it recognises that recyclability is not a binary concept, but depends on multiple factors: the composition of the material, the presence of additives, the compatibility with existing recycling systems, and the quality of the recycled material obtainable.
Accelerating change: a shared responsibility
The process of educating the market is proceeding too slowly compared to the urgency of the environmental challenge we face. A collective commitment is needed from all players in the supply chain:
Manufacturers must take responsibility for communicating the characteristics of their materials in a transparent and scientifically correct manner, resisting the temptation to ride the wave of greenwashing.
Converters and brand owners must deepen their technical knowledge of the materials they use, going beyond superficial declarations and demanding concrete evidence of recyclability.
Regulatory bodies must establish clear and unambiguous criteria to define what can legitimately be defined as “recyclable”, based on the reality of existing recycling infrastructure and not on theoretical possibilities.
End consumers must be informed and sensitised, so that they can make informed choices and reward companies that are truly committed to sustainability.
Alternatives exist and they work
The good news is that technical solutions already exist. At Decofilm, we have demonstrated that it is possible to develop high-performance films without resorting to cross-linking, maintaining all the characteristics required by the most demanding applications while guaranteeing full compatibility with traditional mechanical recycling systems.
These innovative materials are not laboratory prototypes, but industrial products that have already been successfully adopted by major players in the European market. The transition is therefore not only possible, but already underway at the most forward-looking companies.
The challenge of sustainability in packaging is complex, but the solutions exist, at least in DecofilmGroup.
To deepen the issues discussed in this article and evaluate truly sustainable solutions for your packaging needs, the Decofilm technical team is at your complete disposal.