Manual Separation for Material Recovery
Manual separation of packaging materials remains a crucial step in material recovery, with studies showing that improper separation can reduce recycling yields by 20-30%. Current designs often require tools or result in incomplete separation, leaving residual materials that contaminate recycling streams and decrease the quality of recovered materials.
The fundamental challenge lies in creating packaging designs that enable clean material separation while maintaining the structural integrity and protective functions during the product's use phase.
This page brings together solutions from recent research—including tearable PET structures with specific bond ratios, parallel and perpendicular weakening lines, overlapping sections with controlled adhesion, and integrated tear-off mechanisms. These and other approaches focus on achieving complete material separation while preserving package functionality throughout its primary use cycle.
1. Recyclable Packaging Tube with Manually Separable Outer Body and Inner Component
PACKSYS GLOBAL AG, 2024
Recyclable packaging tube that enables easy separation of the tube body from the inner packaging component after use. The tube has a recyclable outer body made of a single material, and the inner packaging component is adapted to the material being stored. The body and inner component are connected reversibly during use, but can be manually separated for recycling after disposal. This allows recycling of the body separately from the inner component, improving overall recyclability compared to tubes with inseparable materials.
2. Blank for Cup Packaging Shell with Perforation System Featuring Curved Engagement Incisions and Variable Length Rectilinear Incisions
PACCOR PACKAGING GMBH, 2023
Blank for a packaging shell of a cup packaging that allows easy separation of the packaging shell from the cup packaging. The blank has a perforation with incisions forming predetermined separation portions. The key features are: 1. Spacing between the upper end of the engagement incision and the lower end of the bottom incision. This prevents accidental splitting of the perforation during handling. 2. Spacing between the upper end of the engagement incision and the lower end of the engagement incision. This allows easier engagement of the perforation for manual separation. 3. Curved engagement incision to spread apart when wound around cup. 4. Rectilinear incisions in upper and lower perforation portions to intensify notching effect. 5. Overlapping incision directions for increased notching effect. 6. Increasing incision length towards central perforation. 7. Project
3. Compact Waste Separation Unit with Manual and Mechanical Processes for On-Site Organic and Packaging Waste Segregation
A, 2022
Micro-scale waste separation unit that can be placed in locations like shopping malls, residential areas, and industrial sites to separate organic waste from packaging waste. The unit is designed to handle 4 tons of waste per day in a 10 m2 space using a combination of manual and mechanical processes. It allows on-site separation of waste at the point of generation instead of transporting mixed waste long distances to centralized facilities. The unit has features like a large clean container for packaging waste, a table to open garbage bags, a knife to cut bag openings, a tub to collect organic waste, and a rotating drum with perforations to extract packaging waste. The unit aims to reduce transportation costs, improve recycling value, and address issues like contamination and hygiene in centralized waste separation facilities.
4. Composite Packaging with Easily Separable Polyolefin and Paper Layers via Selective Adhesive Release Coating
BISCHOF KLEIN SE & CO KG, 2022
Packaging with a composite material wall that can be easily separated into recyclable components for more environmentally friendly disposal. The packaging has a composite wall made of an inner polyolefin layer and an outer paper layer. The adhesive joining the layers is configured to allow hand separation of the paper outer layer from the inner layer and adhesive. This is achieved by having direct bonding between the paper and inner layer in some edge areas, while using a separating lacquer between the adhesive and paper in other areas. This allows the paper to be easily peeled off without destroying the bonded areas. The release coating between the paper and adhesive in the inner region allows the paper to be fully separated from the inner layer and adhesive by hand.
5. Vinyl Bottle Label with Extended Tear Lines for Enhanced Separation
CHOI JEONG-AN, 2022
Plastic bottle packaging vinyl that can be easily opened for recycling by extending the tear lines on the packaging label. The vinyl extension label has a minimum length that can be held with a finger at the upper or lower part of the packaging dotted line. This makes it easier to separate and peel off the label for recycling compared to the regular packaging vinyl that is difficult to tear. The extension label uses the same material as the packaging vinyl for easy separation.
6. Container with Tearable Closure Separation Zone for Easy Recycling
NUTRICIA NV, N.V. Nutricia, NVNUTRICIA, 2021
Packages for powdered products like infant formula that make it easier to separate the container and closure after use for recycling. The separation is facilitated by a designated weakness zone on the container rim. This area can be a line or tear strip with partial perforations or cuts. It allows hand separation of the closure from the container without tools. The closure has a gripping tab on the tear strip. The container wall is paperboard and the closure is plastic. The closure adheres to the container rim with an adhesive. The weakness zone is above the seal to prevent product leakage.
7. Label for PET Bottles with Hand-Removable Adhesive Strip and Cutout Grip Feature
DIC Corporation, 2021
Easy-to-remove label for PET bottles that can significantly increase recycling rates by allowing simple hand removal without tools. The label has a narrow strip of non-printed adhesive tape at one end that can be easily peeled off by hand. This strip can be on the back of the label or as a separate coating layer. The tape or coating is around 5-10mm wide and has cutouts on the top end. This allows easy grip and peeling without affecting the rest of the label.
8. PET Bottle with Detachable Label via Cap Joint Mechanism
KIM DONG WHAN, 2021
PET bottle that can be easily separated and discharged to provide an opportunity for user's attention and change of awareness. The PET bottle includes a label, a bottle cap joint bonded to the PET bottle cap, and a label part torn or removed from the PET bottle by twisting or pulling the bottle cap joint or the connecting portion, or being removed from the PET bottle.
9. PET Bottle with Textured Surface for Manual Label Removal
Dic Co., Ltd., 2020
PET bottle design that allows easy removal of labels by hand, increasing recycling rates. The design involves creating a specific shape and texture on the bottle surface that makes it easier to grip and peel off the label without tools. The shape has raised dots or bumps arranged in a pattern that provides traction when pressing the finger against the label. This allows a user to apply force and lift the label off cleanly. The texture also prevents the label from sticking as tightly, further facilitating manual removal.
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