It was a wet Sunday morning of July in Mumbai when the Professor heard the doorbell ring. A bulky parcel lay at the doorstep — neatly wrapped in shimmering golden plastic, adorned with glossy ribbons and an expensive-looking tag that read: “Let’s go green this Ganesh Chaturthi!”
Ganesh Chaturthi is one of India’s most cherished festivals, celebrating the birth of Lord Ganesha, the remover of obstacles and symbol of wisdom. It brings families and communities together in vibrant devotion, rituals, and cultural expression. Traditionally marked by the installation of Ganesha idols at homes and public pandals, it culminates in the grand visarjan (immersion) ceremony. Beyond faith, the festival represents renewal, gratitude, and the triumph of good beginnings. The festival commences on August 27 and ends on September 6 this year.
“Ah, how thoughtful,” murmured the Professor, adjusting his glasses. Unusual timing. Most corporates wait for Diwali. But this one began its sustainability theatre early.
But as he began to unwrap the parcel, the real journey began. Layer 1 was the outer film – glittery shrink-wrap. Definitely not recyclable and Layer 2 – a laminated cardboard box, embossed with an image of Lord Ganesha. The box Inside was a miniature idol of Lord Ganesha — beautifully crafted, but unmistakably Plaster of Paris (PoP). A sachet of modaks (a sweet and not me – Prasad Modak), wrapped in triple-layered metallized film, and a ‘pesticide-free incense pack’ coated in laminated foil.
“Here we are” Professor muttered — unwrapping goodwill wrapped in guilt.
When I met him for a Sunday breakfast, he reflected not just on this irony, but on the scale of the problem:
- Millions of gift hampers every year
- Each containing dozens of non-recyclable multilayer wrappers
- Unfortunately distributed by brands who flaunt ESG reports and net-zero targets
The Story
Once upon a time, in the golden age of packaging innovation (circa 1980s), engineers and marketers came together with a noble mission: to preserve freshness, extend shelf life, and conquer logistics.
Thus was born Multilayered Plastic (MLP)—a marvel of polymer engineering. Layers of polyethylene for flexibility, PET for strength, aluminium foil for barrier properties, adhesives for staying power. Each one had a job, a role, a function. Much like the bureaucracy of a sustainability committee who often think in silo.
The innovation was celebrated. Biscuits could now travel across states without crumbling. Shampoo could be sold at ₹1, used as per need, avoiding wastage of shampoo and allowing multiple choices on weekdays and weekends. Threats of moisture and oxygen – all defeated! But no one asked: “What happens next?”
Like any good mystery, the real answer is: everyone, and no one.
Corporates
They say they’re committed to sustainability. But in the boardroom, the mantra is: “Unit economics must work.” To them, MLPs are cheap, light, durable—so what if they are ruinous. Most ESG reports mention water, carbon, gender equity… but when it comes to plastics? “We’re exploring alternatives.” Translation: “We’re exploring ways to say something without doing anything.”. So you see impressive events of plastic hackathons that if not well supported often recycle stale innovations.
Consumers
The Professor once asked a rural shopkeeper if he knew what MLPs were. He replied, “Sir, it’s that thing you can’t burn, can’t bury, and does not have a sale price”. But what choice does he have? The economy is sachet-sized, not sustainability-wrapped.
Governments
They issue guidelines. They ban plastic bags. They launch Swachh Bharat selfies. But MLPs? Somehow always find themselves out of scope. Perhaps because enforcement of Extended Producer Responsibility (EPR) has become a compliance game rather than a recovery mechanism.
Scientists and Innovators
The ones who invented MLPs were brilliant. But the ones who were supposed to solve their afterlife seem to have gone on sabbatical. Or are suffering today from research grants slashed by Donald Trump.
But while there are many interventions possible, it’s worth to ask: Has our pursuit of doorstep convenience come at the cost of burdening the environment with unrecoverable waste stream? Our fast-paced lives have distanced us from the neighborhood kirana stores our mothers once frequented—places where shopping was also a conversation. That human connection? Almost gone.
No wonder why Professor loves to redefine MLPs as Modern Littering Protocol or Multiple Layers of Problems.
A Growing MLP Footprint : Thanks to Ecommerce
Today, MLPs are the fastest-growing but least-recyclable segment of the plastic industry. Even with EPR rules in place globally, actual material recovery remains negligible. Most “solutions” are downcycling or energy recovery, not true circularity. Further, Innovations exist but are geographically limited and economically constrained.
India generated 9.5 million tons of plastic waste in 2023 out of which ~3.5 million tonnes (≈37%) was MLP. Since most are rejected by recyclers due to low value, the effective recycling rate is much less than 10%. Visit for more granular information.
Notifications from Central Pollution Control Board between (2022-2024) classify MLPs as “non-recyclable” under India’s Plastic Waste Management Rules unless demonstrated otherwise. Many FMCGs claim to use energy recovery or co-processing, which CPCB does not consider as recycled under EPR norms. Read for more insights especially on the economics
One of the major reasons for the rising Tide of MLP Waste has been E-Commerce. A significant and accelerating driver has been the boom in e-commerce, especially since the COVID-19 pandemic. The COVID-19 pandemic caused a sharp behavioral shift where consumers migrated online for groceries, medicines, personal care, and more. Lockdowns forced first-time digital adoption, even in Tier 2 and 3 towns. And Brands responded by prioritizing freshness, hygiene, and safe delivery — often through multilayered packaging.
MLPs became the packaging of choice due to their:
- Product protection (durable for logistics and long-distance travel)
- Shelf life extension (critical for food, pharma, and cosmetics)
- Branding flexibility (gloss, opacity, clear windows)
- Lightweight structure (lower cost per parcel gram)
MLPs now account for 35–45% of all flexible packaging. In e-commerce-dominant categories, MLP use is growing 2–3× faster than rigid packaging. Platforms like Amazon, Flipkart, Nykaa, and BigBasket have introduced millions of single-use multilayer sachets and pouches.
If this trend continues, MLPs could exceed 50% of all flexible plastic waste in developing countries by 2030. Circularity will remain a myth unless:
- E-commerce platforms commit to recyclable or biodegradable alternatives
- EPR is tightly enforced across digital retail ecosystems
- Consumers become aware not just of what’s inside, but how it’s wrapped
It’s time to ask: In our quest for doorstep convenience, are we wrapping our environment in irreversible waste?
Today, over 70 countries globally operate some form of packaging EPR. The EU is particularly proactive in including e-commerce in its regulations—marketplaces cannot operate unless sellers are EPR compliant. In the US, several progressive states have adapted packaging laws to explicitly cover online sellers. Countries such as India, Thailand and Indonesia recognize e-commerce as part of the producer responsibility chain, though the strength and enforcement vary. India and Indonesia already include ecommerce sellers under their EPR frameworks; Thailand is rapidly moving toward mandatory inclusion. This marks a crucial shift: the digital economy can’t dodge accountability for packaging waste. See What is Extended Producer Responsibility (EPR) & How do Plastic Credits Fit In? by Sarah Hadley for more information.
Enabling policies with global-forge impact, this integration is crucial given the surge of MLP waste tied to online shopping. This means that progressive policies should be forged first locally to influence policies globally. When you compel e-commerce giants to shoulder packaging responsibility, you’re not just changing compliance in one country — you’re forging a new standard for the entire digital economy.
The Way Forward: From Satire to Solutions
But we still have a hope in Layers as initiatives are emerging to tackling the MLP Problem. Examples in India are by Hindustan Unilever + UNDP + Local Governments: The Swachhata Kendras Initiative to divert MLPs to cement kilns, NEPRA Foundation’s Collaboration on Integrated MLP recovery at MRFs, Banyan Nation –Data-Driven Collection followed by R&D on chemical recycling for complex MLPs, ITC’s Wellbeing Out of Waste (WOW) Program where segregation is done to co-process of low-value plastics
I did some internet research for Professor and found few interesting global good practices in MLP waste management.
Design for Recycling & Layer Optimization
CEFLEX (Europe): Developed D4ACE guidelines encouraging mono-material laminates and minimization of aluminum or PET barriers. CEFLEX is a European consortium involving over 180 stakeholders in the flexible packaging value chain. Their flagship initiative, Design for a Circular Economy (D4ACE), promotes the development of mono-material films that reduce layer complexity and enhance recyclability. By minimizing use of aluminum or PET barriers and promoting PE/PE or PP/PP laminates, CEFLEX helps brands maintain product integrity while ensuring compatibility with existing mechanical recycling infrastructure. Other examples include BASF (Germany): Reduced a 5-layer MLP to 3-layer through barrier coatings and chemical recycling and Nestlé used data analytics to optimize packaging based on shelf life prediction tool
Full Value Chain Collaboration Models
Project STOP – Muncar, Indonesia :Combines segregation, pyrolysis, and FMCG engagement to reduce MLP waste. Project STOP, initiated by Borealis and SYSTEMIQ in Muncar, aims to create circular waste systems in Southeast Asia. The project works directly with municipalities to improve collection and sorting of MLPs and uses small-scale pyrolysis to handle residual non-recyclables. The program has seen over 50% improvement in plastic waste collection rates and has demonstrated the importance of integrating local livelihoods in waste value chains. Visit the project website to learn more
In essence, we should design packaging with death in mind, not just shelf life. Implement EPR with teeth — not while chewing a sachet of tobacco. Consider setting up Mobile Microfactories for MLP recycling, especially in rural India, employing local youth. And yes, Governments could disincentivize MLP use with a ‘Layer Tax’ — every extra layer pays double. Make recyclability financially rewarding.
Readers are recommended to see a review article “A state-of-the-art review of multilayer packaging recycling: Challenges, alternatives, and outlook”
Final Musings
Nature rarely does multilayer. An orange has one peel. A banana needs just one skin with no barcode. Even a coconut comes in biodegradable, beverage-compatible packaging.
But we? We wrap our food, our soap, and so our planet in layers of denial.
As the Professor gazed at the gift box still glinting on his desk, he whispered:
“You are not just non-recyclable and so are unforgettable.”
If MLP is the problem, then MLC – Multi-Layered Collaboration – must be the solution.
Let researchers, regulators, ragpickers, retailers, recyclers and responsible consumers form a true circular alliance. Because in the end, solving a multi-layered problem needs multi-layered resolve.
So let’s not gift-wrap our guilt anymore. The planet deserves better packaging — and with better promises.
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Your blog post this Sunday was exceptionally resourceful in terms of highlighting the menace of MLP, sharing facts & research on this global menace which is wilfully being overlooked by most lazy leaders. The need for collaboration among the 6Rs stakeholders (Researchers, Regulators, Ragpickers, Retailers, Recyclers and Responsible Consumers) offers hope. The meaningful initiatives from several communities, companies and countries offer hope against this multi layered problem called MLP. Thank you!