Thermal degradation and hydrolysis depolymerization of printing ink components for plastic packaging in recycling processes: a review

Highlights

● Identifies and elucidates the concurrent thermal degradation and hydrolysis of common binders in flexible plastic packaging during mechanical recycling.

● Reveals that thermal degradation for a variety of binder resins begins between 200–300 °C, with hydrolysis potentially intensified by humidity from cleaning processes.

● Demonstrates how the compatibility between binder resins and polyolefin affects the quality of recycled plastics, emphasizing this issue regarding immiscibility.

● Underscores the influence of binder resins and their degradation products on the efficacy of advanced recycling methods like selective dissolution-precipitation and pyrolysis.

Abstract

This review covers the decomposition mechanisms of various printing ink binder resins, with a particular focus on their behavior under extrusion conditions in the mechanical recycling process of polyolefin (PO) based plastic packaging. Thermal degradation and hydrolysis of the nitrocellulose (NC) ─ the most used binder for flexographic surface printing on single-layer flexible plastic packaging, occur concurrently during the mechanical recycling process under 160–210 °C. For other printing ink binders, polyurethane (PU) noticeable degradation takes place between 200 and 300 °C, mostly above 250 °C. However, with the involvement of humidity, degradation by hydrolysis can start from 150 °C. A similar effect is also discovered with the cellulose acetate (CA) derivatives, which are thermally stable until 300 °C and can be hydrolyzed at 100 °C. The thermal stability of polyvinyl butyral (PVB) is not influenced by humidity, with thermal stability ranging from 170 to 260 °C, depending on different types. Ultraviolet (UV)-cured acrylics are thermally stable until 400 °C. The hydrolysis degradation can take place at room temperature. Moreover, this review covers the thermal stability of different colorants used for printing ink application and elaborates on several thermal-stable alternatives of some common colors. This study further reviews how the binder resin affects the quality of recyclates, revealing it to be not only induced by the degradation of the binder resin but also by the immiscibility between the plastic and binder resin. In advanced recycling processes, mainly selective dissolution-precipitation and pyrolysis, the presence of binder resin and its degradation products could still affect the quality of the product. This review accentuates the imperative need for in-depth research to unravel the impact of printing ink constituents on the quality of recycled products.

Graphical abstract

Keywords

Plastic recycling / Flexible packaging / Polymer degradation / Green chemistry

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