Coatings for fully recyclable plastics
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How could this innovative technology help to reduce plastic pollution?
Spotted: Plastic waste is one of the most pressing environmental challenges of our time. Only an estimated nine per cent of all plastics ever produced have been recycled. The rest is incinerated, landfilled, or ends up in the environment, contributing to pollution and greenhouse gas emissions. Addressing this, a German startup is helping to make plastic packaging more circular with a plasma-enhanced chemical vapour deposition (PECVD) process.
Founded in 2021 as a spin-off from the RWTH Aachen Institute of Plastics Processing, IonKraft has developed a recyclable, PFAS-free coating technology. Using PECVD, the process creates a glass-like silicon oxide barrier layer on common plastics such as PET and PE-HD. This ultra-thin coating – measuring under 100 nanometres – is chemically inert and non-reactive, enabling the recycling of materials while maintaining the protective qualities required for food, cosmetics, and other sensitive products.
IonKraft’s innovation stands out for its ability to integrate seamlessly into existing manufacturing lines. Unlike multi-layer or PFAS-containing packaging that is difficult to recycle, IonKraft’s coatings are certified recyclable by Recyclass. The technology also avoids the fragility of glass packaging, providing manufacturers with a sustainable yet practical alternative.
With €3.5 million in fresh funding (granted in November 2024) from investors like M Ventures, TechVision Fund, and HTGF, IonKraft is scaling up. The company is installing its first coating plant at a customer site this year, with products expected to launch in 2025. Having already secured EU support through the EIC Accelerator programme, IonKraft is well-positioned to meet growing regulatory and market demands for sustainable packaging solutions.
Written By: Oscar Williams