A “major step forward in advanced recycling of flexible films” has taken place at Coveris’ ReCover site in Louth, Lincolnshire, UK, the company claims, after a new “first-of-its-kind” demonstration plant with a “breakthrough” purification technology for post-consumer polyolefin (PE and PP) film waste became operational.
The COtooCLEAN plant has been developed by Coveris and the sustainability technology consultancy Nextek, supported by the Alliance to End Plastic Waste, and is designed to address the persistent issue of embedded contaminants in plastic films. Using supercritical CO₂ extraction, the process penetrates deep into the polymer structure to remove oils, odours and legacy substances that conventional mechanical recycling cannot fully eliminate, enabling conversion into high-quality recycled resin suitable for food-grade applications.
Coveris said the current operational phase represents a critical preparation step in tackling the complex challenge of enabling safe, compliant food-grade recycling from post-consumer flexible packaging. A subsequent industrial trial phase, due to begin this month, will enable the development of larger-scale operational experience and the generation of the two years of data required for European regulatory approval, while demonstrating both scalability and commercial viability.
According to Edward Kosior, founder of Nextek, COtooCLEAN’s high purification performance provides a critical complementary step to unlock higher-quality recycled materials and enable true circularity for flexible films. By enabling significantly higher decontamination performance, the technology promises to pave the way for increased availability of food-grade recycled content by supporting regulatory compliance and reducing reliance on virgin materials.
“This project marks the next step in advancing Coveris’ No Waste vision, with ReCover playing a central role in keeping plastics circular,” said Bernhard Mumelter, group innovation manager at Coveris Group.
“With COtooCLEAN now fully operational, we are taking an important step in preparing to solve the food-grade recycling challenge for flexible films. Together with our advanced de-inking technologies, this innovation strengthens our mechanical recycling capabilities and opens the next phase of solutions for more demanding applications.”
Jacob Duer, president and CEO of the Alliance to End Plastic Waste, added: “COtooCLEAN has the potential to improve both the rate and quality of flexible plastics recycling. This demonstration plant is an important step in validating the technology and supporting its path to wider deployment. It also reflects the Alliance’s commitment to advancing practical, scalable solutions. By accelerating innovation and working with partners across the value chain, we are working to turn progress into real systems change.”
