Advances and challenges in production and valorization of biaxially oriented polypropylene (BOPP)

The extensive use of biaxially oriented polypropylene (BOPP) in various industries poses significant environmental challenges due to its resistance to degradation and complex recycling processes. This study reviews the historical evolution, production processes, and recycling/valorization practices of BOPP films, identifying emerging trends and future directions to enhance their sustainability. Recycling BOPP faces challenges due to its complexity, high orientation, and contamination. Methods including low-temperature mechanical recycling, nano-enhancement, mechanical recycling into composites, and chemical recycling through processes like pyrolysis have been applied to address these issues and promote a circular economy. To improve sustainability, researchers are developing biodegradable BOPP films, energy-efficient production processes, and reducing material usage through downgauging. © 2025 Elsevier B.V., All rights reserved.