BeFORE | Barrier FOr REcycling

Region:

Flanders

Financed by

Understanding how processing impacts packaging performance and recyclability

High-barrier plastic and paper packaging is essential to protect sensitive products such as food, pet food and cosmetics, while extending shelf life. However, most current high-barrier packaging solutions remain difficult to recycle because of their multi-material structures. BeFORE explores how innovative barrier materials can improve the recyclability of flexible packaging while maintaining performance under realistic processing and usage conditions.

Target group

The project is relevant for:

Packaging designers and manufacturers
Companies active in cosmetic packaging
Food packaging companies
Pet food packaging companies

Context

The new Packaging and Packaging Waste Regulation (PPWR) accelerates the transition towards fully recyclable packaging. This creates major challenges for high-barrier materials, which are often incompatible with existing recycling streams.

At the same time, new recyclable barrier solutions are emerging. However, their durability during converting and processing steps, as well as their real-life barrier performance, remain uncertain.

SMEs currently lack standardised methods and reliable data to evaluate how processing impacts barrier properties, recyclability and packaging performance. This limits the development of packaging solutions that successfully balance product protection and circularity.

Objectives & results

BeFORE brings together seven partners across Belgium, Germany and Poland to improve the design-for-recycling of high-barrier packaging materials.

Main objectives:

Build an inventory of barrier materials and processing technologies
Identify and shortlist the most promising recyclable barrier materials
Develop laboratory protocols simulating critical processing steps
Analyse the impact of processing on barrier, mechanical and thermal properties
Assess recyclability using standardised methods for paper and plastic packaging
Validate packaging concepts through real industrial case studies
Develop guidelines and recommendations for packaging SMEs

Key expected results:

A database covering at least 20 high-barrier materials and relevant processing steps
Validation of at least six industrial case studies
Design guidelines and best-practice recommendations
Workshops, webinars and knowledge transfer activities for SMEs

Approach

The project is structured into several work packages:

WP1 – Inventory of materials

Collection of data on barrier materials and processing steps (TDS, literature, industry input)
Selection of promising materials and industrial case studies

WP2 – Processing and modification of packaging materials

Application of coatings on plastic and paper substrates
Development of laboratory protocols simulating industrial processing conditions (thermoforming, abrasion, puncture)

WP3 – Characterisation of materials

Testing of barrier (OTR, WVTR), mechanical, thermal and surface properties
Evaluation of the influence of processing on material performance

WP4 – Recyclability assessment

Evaluation of recyclability using standardised plastic and paper recycling protocols
Laboratory-scale recycling trials and recommendations for improvement

WP5 – Legislative aspects

Analysis of European regulations such as PPWR and FCM
Compliance assessment and migration calculations for selected materials

WP6 – Case studies

Validation in six to eight real packaging applications
Shelf-life modelling and storage tests under realistic conditions

WP7 – Dissemination and communication

Development of practical guidelines and FAQ documents
Workshops, webinars and knowledge transfer towards SMEs

Looking to develop more recyclable high-barrier packaging?

Discover how processing impacts recyclability and barrier performance. Join our workshops, access practical project insights and exchange with experts on recyclable packaging solutions for paper and plastic applications.

Contact Arne Derluyn