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Polymers for Circular Packaging Materials
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Polymers for Circular Packaging Materials

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Applications".

Deadline for manuscript submissions: 31 August 2025 | Viewed by 3807

Special Issue Editors

Prof. Dr. Marek Hauptmann

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Guest Editor
Division Processing Technology, Fraunhofer Institute for Process Engineering and Packaging IVV, Dresden, Germany
Interests: packaging technologies and processes; sealing; forming of polymers and papers; material characterization; inline monitoring; packaging development; machine runnability; packaging machine behavior
Dr. Frank Welle

E-Mail
Guest Editor
Department Product Safety and Analytics, Fraunhofer Institute for Process Engineering and Packaging IVV, Freising, Germany
Interests: food contact materials; migration testing; permeation testing; diffusion modeling; diffusion of substances in polymers; non-intentionally added substances (NIASs); functional barrier testing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Our permanently growing demand for packaging materials with a wide variety of different requirement profiles and the urgent necessity of circular material flows to preserve material and resource values are generating the crucial challenge of a consistent functional and circular use of polymers in packaging applications. The protective nature of the packaging requires using polymers in very different forms, ranging from natural or synthetic multilayer films to polymeric layers on natural fiber-based material or used as additives within base materials and functional layers. Each polymer is intended to add a certain function, but more than ever before, each component used in the packaging materials needs to be chosen with respect to its specific value or impact on material cycles after their first usage.

We are pleased to invite you to share your research on the use of polymers for the overall improvement of packaging material performances, focusing on combining their efficient and functional application, the achievement of new or improved material and packaging properties, and their performances in value-keeping loops. This Special Issue intends to contribute to an overarching understanding of the following topics:

  • Molecular properties and changes in the molecular structure of polymers, including intentionally added substances and the appearance of non-intentionally added substances and their affinity to migrate into the packed products;
  • The emerging macroscopic processing properties and their changes during the lifetime of the packaging POLYMERS due to thermodynamic or mechanical load or deterioration;
  • The specific behavior achieved by polymers in the particular processes of packaging machines.

We strongly encourage you to submit original research on the use, value, and performance of polymers from new recyclable, secondary, natural, and residual resources in packaging material to improve its function independent of whether they are used as an additive, layer or composite structure in or on polymeric or paper substrate. The contributions may address all kinds of packaging functions and those functions needed during the processing on packaging machines, such as strength, rigidity, ductility, strain, sealing, barrier against water vapor, oxygen or migration of harmful substances, chemical or mechanical resistance, odor, printing behavior, prints and decoration and tribological properties. Due to the fact that tailored layer structures can achieve many functional profiles of packaging materials, articles may also address modifications and scaling of coating technologies.

Within the material production, coating, and packaging processes, we expect that modeling and simulation techniques using analytical, numerical, or heuristic methods, including artificial intelligence, are needed to explain the origin of recognized phenomena, and we support their use and introduction within the submitted articles.

Prof. Dr. Marek Hauptmann
Dr. Frank Welle
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • circular packaging materials
  • paper coatings and functional cellulose
  • recyclates and recyclate processing
  • polymer additives
  • printing and decoration
  • packaging process behavior
  • compliance and packaging safety
  • migration and diffusion
  • chemical analysis
  • biobased polymers
  • barrier, sealant layer
  • numerical modeling and artificial intelligence
  • alternative resources and residues

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (5 papers)

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Research

16 pages, 3129 KiB  
Article
Development of PP Compound Recipes Using Genetic Algorithms and Analytical Models
by Lukas Seifert, Lisa Leuchtenberger-Engel and Christian Hopmann
Polymers 2025, 17(8), 1059; https://doi.org/10.3390/polym17081059 - 14 Apr 2025
Viewed by 214
Abstract
This study explores the development of polypropylene (PP) compound recipes using analytical models (AM) combined with genetic algorithms (GAs). A talcum-filled PP compound, commonly utilised in injection moulding for packaging applications, served as a reference material, with shear viscosity, tensile modulus, and impact [...] Read more.
This study explores the development of polypropylene (PP) compound recipes using analytical models (AM) combined with genetic algorithms (GAs). A talcum-filled PP compound, commonly utilised in injection moulding for packaging applications, served as a reference material, with shear viscosity, tensile modulus, and impact strength selected as target properties for replication. The AM were adapted and fitted to a dataset of 52 compounds, achieving high predictive accuracy for shear viscosity and tensile modulus, while impact strength proved more challenging due to its inherent variability. Three recipes were generated using GA under predefined material constraints. Recipe 1 aimed to replicate all three target properties, achieving a balanced compromise with maximum deviations of 13.14% for tensile modulus and 12.37% for impact strength while closely matching shear viscosity (maximum 9.8% deviation). Recipes 2 and 3, focused solely on matching shear viscosity and impact strength, demonstrated exceptional accuracy for shear viscosity, with Recipe 2 achieving near-perfect alignment (2.5% deviation). However, neither recipe approached the tensile modulus target due to material limitations. The findings demonstrate the effectiveness of combining AM with GA for designing alternative formulations, emphasising the importance of realistic targets and material constraints. This methodology is highly adaptable, allowing for the inclusion of additional optimisation criteria such as cost or sustainability. Future work will explore broader material sets and properties, extending the framework’s applicability to technical polymers and diverse industrial applications. Full article
(This article belongs to the Special Issue Polymers for Circular Packaging Materials)
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19 pages, 3240 KiB  
Article
Model-Based Prediction of the Tensile Properties of Polypropylene Films Made from Recycled Materials
by Marius Stieglitz, Sonja Adomeit, Marisa Müller, Karina Hettwer, Anja Schlierf, Steffen Uhlig, Sarah David, Christian Hopmann and Lisa Leuchtenberger-Engel
Polymers 2025, 17(8), 1044; https://doi.org/10.3390/polym17081044 - 12 Apr 2025
Viewed by 255
Abstract
This study investigates the potential of data-driven modeling to monitor and predict mechanical properties of extruded film using recyclates. The first step is to investigate whether a process parameter can indicate the input material quality of the material, which can vary significantly due [...] Read more.
This study investigates the potential of data-driven modeling to monitor and predict mechanical properties of extruded film using recyclates. The first step is to investigate whether a process parameter can indicate the input material quality of the material, which can vary significantly due to the use of recyclate. The die pressure was shown to be a key indicator due to its strong correlation with viscosity and material degradation. The second step is to explore the ability of machine learning models—Generalized Additive Models, Linear Regression, and Random Forest—to predict film tensile strength and modulus based on extrusion process and material parameters. The results demonstrate that including Melt Flow Rate and shear viscosity in addition to pressure and feedstock type (Virgin, PIR, and PCR) significantly improves model accuracy, with Generalized Additive Models achieving the highest R2 of 85.7% for tensile strength prediction. Additionally, the observed variability between different recyclate streams highlights the need for a more detailed classification of recyclates to better predict and optimize the mechanical performance of the film. While data-driven approaches for predicting properties show promise, their effectiveness remains limited by data availability and feedstock variability. Expanding datasets and improving process stability will be critical to refining predictive models for industrial application. Full article
(This article belongs to the Special Issue Polymers for Circular Packaging Materials)
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15 pages, 2099 KiB  
Article
Development of an Analytical Model for Predicting the Shear Viscosity of Polypropylene Compounds
by Lukas Seifert, Lisa Leuchtenberger-Engel and Christian Hopmann
Polymers 2025, 17(2), 126; https://doi.org/10.3390/polym17020126 - 7 Jan 2025
Cited by 1 | Viewed by 848
Abstract
The need for an efficient adaptation of existing polypropylene (PP) formulations or the creation of new formulations has become increasingly important in various industries. Variations in viscosity resulting from changes in raw materials, fillers, and additives can have a significant impact on the [...] Read more.
The need for an efficient adaptation of existing polypropylene (PP) formulations or the creation of new formulations has become increasingly important in various industries. Variations in viscosity resulting from changes in raw materials, fillers, and additives can have a significant impact on the processing and quality of PP products. This study presents the development of an analytical model designed to predict the shear viscosity of complex PP blends. By integrating established mixing rules with novel fitting parameters, the model provides a systematic and efficient method for managing variability in PP formulations. Experimental data from binary and multi-component blends were used to validate the model, demonstrating high prediction accuracy over a range of shear rates. The proposed model serves as a valuable tool for compounders and manufacturers to optimise PP formulations and develop new recipes with consistent processing and product quality. Future work will include industrial-scale trials and further evaluation against advanced machine learning approaches. Full article
(This article belongs to the Special Issue Polymers for Circular Packaging Materials)
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15 pages, 3040 KiB  
Article
Impact of Citric Acid on the Structure, Barrier, and Tensile Properties of Esterified/Cross-Linked Potato Peel-Based Films and Coatings
by Katharina Miller, Corina L. Reichert, Markus Schmid and Myriam Loeffler
Polymers 2024, 16(24), 3506; https://doi.org/10.3390/polym16243506 - 17 Dec 2024
Cited by 1 | Viewed by 1047
Abstract
The valorization of potato peel side streams for food packaging applications, especially for the substitution of current petrochemical-based oxygen barrier solutions such as EVOH, is becoming increasingly important. Therefore, potato peel-based films and coatings (on PLA) were developed containing 10–50% (w/ [...] Read more.
The valorization of potato peel side streams for food packaging applications, especially for the substitution of current petrochemical-based oxygen barrier solutions such as EVOH, is becoming increasingly important. Therefore, potato peel-based films and coatings (on PLA) were developed containing 10–50% (w/w potato peel) citric acid (CA). To determine the impact of CA concentration on the structure and physicochemical properties of cast films and coatings, ATR-FTIR spectroscopy, moisture adsorption isotherms, tensile properties, light transmittance, oxygen permeability, carbon dioxide transmission rate, and water vapor transmission rate measurements were performed. The results indicate that an increase in CA concentration from 10% to 30% increased esterification/cross-linking and resulted in minimal values for the oxygen permeability (0.08 cm3 m−2 d−1 bar−1) at 50% RH and water vapor transmission rate (1.6 g m−2 d−1) at 50% → 0% RH, whereas an increase from 30% to 50% increased free CA concentration and resulted in increased flexibility, indicating that CA functioned as a plasticizer within the film/coating at higher concentrations. Overall, potato peel-based coatings containing CA showed comparable barrier properties to EVOH. We assume that an extensive industrial purification or fractionation of potato peel, which was not carried out in this study, could lead to even lower transmission rates. Full article
(This article belongs to the Special Issue Polymers for Circular Packaging Materials)
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Graphical abstract

20 pages, 3204 KiB  
Article
Development of an Analytical Model for Predicting the Tensile Modulus of Complex Polypropylene Compounds
by Lukas Seifert, Lisa Leuchtenberger-Engel and Christian Hopmann
Polymers 2024, 16(23), 3403; https://doi.org/10.3390/polym16233403 - 3 Dec 2024
Cited by 3 | Viewed by 905
Abstract
The extensive use of polypropylene (PP) in various industries necessitates the development of efficient and reliable methods for predicting the mechanical properties of PP compounds. This study presents the development of an analytical model (AM) designed to predict the tensile modulus for a [...] Read more.
The extensive use of polypropylene (PP) in various industries necessitates the development of efficient and reliable methods for predicting the mechanical properties of PP compounds. This study presents the development of an analytical model (AM) designed to predict the tensile modulus for a dataset of 64 PP compounds with various fillers and additives, including chalk, impact strength modifiers, and peroxide additives. The AM, incorporating both logarithmic and linear components, was benchmarked against an artificial neural network (ANN) to evaluate its performance. The results demonstrate that the AM consistently outperforms the ANN, achieving lower mean absolute error (MAE) and higher coefficient of determination (R2) values. A maximum R2 of 0.98 could be achieved in predicting the tensile modulus. The simplicity and robustness of the AM with its 14 fitting parameters compared to the ~1300 parameters of the ANN make it a useful tool for the plastics industry, providing a practical approach to optimising compound formulations with minimal empirical testing. Full article
(This article belongs to the Special Issue Polymers for Circular Packaging Materials)
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