While there has been an admirable focus on creating a “circular economy” when it comes to recycling plastics, some practical risk concerns are emerging that should be addressed as we fill in the gaps in that circle.
In short, just because plastic from bottles and containers is recycled and considered sustainable does not make it risk-free. Especially for food-grade contact materials, recycled plastics may release metals, phthalates, persistent organic pollutants and other harmful chemicals not aligned with the safe end use of plastic. This is particularly concerning for resins that have been through several recycling life cycles.
These risks are driven primarily by waste streams inadvertently mixing food-grade and non-food plastics, potential exposure to pesticides or pharmaceuticals, and “post-consumer misuse,” such as storing chemical cleaners or fuels in plastic bottles. Re-use will eventually result in plastics that have been used in multiple service life cycles. However, knowledge gaps remain regarding the impact of the number of life cycles on the fate of additives and their influence on physical properties.
A Risk-Based Approach
The IAFNS Food Packaging Safety & Sustainability Committee carries out a research agenda focused on safe packaging and so-called “non-intentionally added substances” or NIAS. This effort will generate an in-depth survey of the plastic recycling landscape and identify safety issues and potential solutions to the increased adoption of recycled plastic. Results will also identify restricted and NIASs in recycled material along with mitigation options to advance “clean” recycled plastics for safe re-use, especially in food contact applications.
Upcoming research will utilize virgin and post-consumer plastics to increase the understanding of the physical and chemical property changes and migration potential as a function of simulated life cycles.
This effort also will pursue common standards that define grades of Post-Consumer Recycled (PCR) plastics with necessary performance properties and regulatory compliance — including for food contact materials — by linking them with their end uses. It will also focus on performance properties and the regulatory compliance of PCR plastic markets especially given that using virgin plastic for food packaging may be less risky than recycled plastic at this juncture in the US.
IAFNS Research
Increasing Use of Recycled Polypropylene: IAFNS-supported researchers analyzed the physical properties and contaminants/residual additives in PCR polypropylene, providing guidance to improve cleaning, separation processes and reduce landfilling. Polypropylene is commonly used in detergent bottles and food containers. These data indicate careful sorting is required to reduce exposure to chemicals of concern and unapproved additives in food packaging made with PCR polypropylene.
Wash Water for Recycled Plastics: This study addresses the quality of post-consumer plastic wash water, which is essential for safe recycled plastic production, especially in food-contact applications. The water used to clean incoming recycled plastic is often re-used, accumulating contaminants along the way. The study highlights that ultrasonication and surfactant-based washing generate more wastewater contaminated with phthalates, bisphenols and other contaminants. More attention and monitoring of wash water may be warranted.
Restricted Substances Lists (RSL): No standardized RSL exists for food contact materials (FCMs), though many packaging RSLs have similar compounds and thresholds. This makes it challenging to manufacture products complying with regulatory and diverse RSL requirements across different jurisdictions. Therefore, compiling these regulated/restricted substances is imperative to formulating a thorough reference for stakeholders and manufacturers. This IAFNS-supported study describes regulations, threshold limits, and typical food contact applications from RSLs developed by domestic and international stakeholders.
Consumer Demand Driving Recycling
While these risk challenges remain, consumer demand for sustainable packaging continues to shape industry decisions. A study done in the meat and poultry sector found that sustainability significantly influences purchasing choices, especially among the millennial generation. Reducing plastic use and increasing recyclability are top priorities, with 34% of consumers favoring less plastic and 30% seeking recyclable packaging, according to the study.
The future is likely to involve stricter use-based sorting, implementing “challenge tests” to validate plastic cleaning processes, and broadening the use and impact of RSLs for recycling operations.
With a careful, science-based approach, recycled plastic packaging can be both sustainable and relatively safe as we move toward a more circular economy. Join us as we map a sustainable and safer future for food contact packaging and other recycled plastics through research, programming and insight.
Neal Saab, PhD, is Director of Food Safety Program at IAFNS and brings over 30 years of experience in research, risk assessment, advocacy and regulation of biotechnology and emerging technologies. His multi-sector experiences in regulatory agency engagement, science leadership, project management and capacity building make him uniquely qualified to lead food, chemical, and sustainability committees at IAFNS.
Steve Gibb, MS, focuses on mobilizing knowledge on food safety, nutrition and sustainable packaging topics. Previously he worked as an award-winning environmental science reporter with Bloomberg News. Prior to that he worked as a federal contractor supporting USDA, EPA and DOD.