Nextek, Coveris start COtooCLEAN plant in Lincolnshire to recycle food-grade flexible films

UK – Nextek and Coveris have started operating a demonstration recycling plant using supercritical CO₂ extraction to remove contaminants from post-consumer polyolefin film waste, producing recycled resin for potential food-contact uses.

The COtooCLEAN plant moved into an industrial phase in April 2026 at Coveris’ ReCover facility in Lincolnshire, UK.

Built with financial support from the Alliance to End Plastic Waste, the technology addresses contamination that standard mechanical recycling methods cannot fully remove.

Industrial-scale trials are due to begin this month and are intended to generate the two years of data required by European regulators.

The Technology Behind COtooCLEAN

Standard mechanical recycling of flexible plastic films is limited by contamination. Food residues, adhesives, printing inks, and odours can remain embedded in the plastic, rendering the recycled material unsuitable for high-value applications such as food-contact packaging.

COtooCLEAN uses supercritical CO₂, carbon dioxide at a temperature and pressure where it behaves as both a liquid and a gas, to penetrate the plastic matrix and extract contaminants at a molecular level.

The process is designed to complement mechanical recycling, not replace it, by providing a polishing step for materials that have already been washed and shredded.

Why Food-Grade Recycled Flexible Film Matters

Flexible films dominate consumer packaging for bread, fresh produce, frozen foods, and snacks. Unlike rigid bottles, which have established recycling streams and regulatory approval for food-contact recycled content, flexible films have struggled to achieve the same level of circularity.

European regulations require rigorous decontamination data before approving recycled materials for food contact. The COtooCLEAN demonstration plant is designed to generate precisely that data.

Edward Kosior, founder of Nextek, explained that COtooCLEAN offers a critical complementary step to unlock higher-quality recycled materials and enable true circularity for flexible films.

Jacob Duer, president and CEO of the Alliance to End Plastic Waste, noted that COtooCLEAN has the potential to improve both the rate and quality of flexible plastics recycling.

A Shared Vision

Bernhard Mumelter, Coveris Group innovation manager, commented that this project marks the next step in advancing Coveris’ No Waste vision, with ReCover playing a central role in keeping plastics circular.

With COtooCLEAN now fully operational, he said the company is taking an important step in preparing to solve the food-grade recycling challenge for flexible films.

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