Analytical protocol to study the food safety of (multiple-)recycled high-density polyethylene (HDPE) and polypropylene (PP) crates: Influence of recycling on the migration and formation of degradation products

Role of quality assessment of the recycled packaging material in determining its safety profile as food contact material

Food packaging waste significantly impacts global environmental changes, prompting the adoption of a green circular economy approach. Recycling packaging waste is a critical element of this strategy. However, it faces challenges related to the quality of recycled materials and concerns about their safety. Thus, this review aimed to highlight different analytical methods alone or in combination to evaluate the quality of the recycled material. Furthermore, the safety and health aspects related to the migration of contaminants and their relevant regulations have also been discussed. An important parameter while selecting an appropriate recycling method is the composition and nature of the recyclate, for instance, HDPE (High-Density Polyethylene), PET (Polyethylene Terephthalate), and PP (Polypropylene) materials can be recycled using mechanical and chemical recycling, however, PVC (Polyvinyl Chloride) and PS (Polystyrene) present challenges during mechanical recycling due to lower molecular weight and complex compositions, thus are often downcycled into lower-grade products. Still, recycled papers can be more problematic than recycled plastics due to the nature of the materials and the impact of recycling. The literature review suggested that three quality properties i.e., presence of low molecular weight compounds, degree of degradation, and composition should be analyzed by using different spectroscopic, thermo-mechanical, and chromatographic techniques to obtain a detailed understanding of recycled material quality. Furthermore, recycling should be done in such a way that the migration of contaminants should be lower than the migratory limits set by the relevant authorities to avoid any toxicological effects.

Revealing the long-term impact of photodegradation and fragmentation on HDPE in the marine environment: Origins of microplastics and dissolved organics

The extensive usage of high-density polyethylene (HDPE) materials in marine environments raises concerns about their potential contribution to plastic pollution. Various factors contribute to the degradation of HDPE in marine environments, including UV radiation, seawater hydrolysis, biodegradation, and mechanical stress. Despite their supposed long lifespans, there is still a lack of understanding about the long-term degradation mechanisms that cause weathering of seawater-exposed HDPE products. In this research, the impact of UV radiation on the degradation of HDPE pile sleeves was studied in natural as well as laboratory settings to isolate the UV effect. After nine years of exposure to the marine environment in natural settings, the HDPE pile sleeves exhibited an increase in oxygen-containing surface functional groups and more morphological changes compared to accelerated UVB irradiation in the laboratory. This indicated that combined non-UV mechanisms may play a major role in HDPE degradation than UV irradiation alone. However, UVB irradiation was found to release dissolved organic carbon and total dissolved nitrogen from HDPE pile sleeves, reaching levels of up to 15 mg/L and 2 mg/L, respectively. Our findings underscore the significance of taking into account both UV and non-UV degradation mechanisms when evaluating the role of HDPE in contributing to marine plastic pollution.

Influence Analysis of Modified Polymers as a Marking Agent for Material Tracing during Cyclic Injection Molding

Injection molding (IM) is already an established technology for manufacturing polymer products. However, in the course of the increased use of recyclates for economic and ecological reasons, its application capability has been confronted with new requirements for reliability and reproducibility. In addition, the IM process is confronted with regulations regarding a verifiable recycling degree in polymers. With regard to the material identification and storage of manufacturer-, process- or product-related data in polymers, the implementation of a material-inherent marking technology forms a potential answer. The IM process combined with modified polymers (MP) as a marking technology turns out to be a feasible approach to manufacturing reproducibly and offers a high quality based on increased process awareness and fulfilling the required traceability. Therefore, this work focuses on the trial evaluation of MP within the IM process. The influence of MP on the material process behavior and mechanical and thermal component properties, as well as the influence of the IM process and recycling on MP traceability, are investigated. No discernible influences of MP on the investigated properties could be identified, and the traceability from the initial material to a recyclate could be confirmed. MP is suitable for monitoring the aging state of polymers in IM.

Unpacking the complexity of the polyethylene food contact articles value chain: A chemicals perspective

Polyethylene (PE) is the most widely used type of plastic food packaging, in which chemicals can potentially migrate into packaged foods. The implications of using and recycling PE from a chemical perspective remain underexplored. This study is a systematic evidence map of 116 studies looking at the migration of food contact chemicals (FCCs) across the lifecycle of PE food packaging. It identified a total of 377 FCCs, of which 211 were detected to migrate from PE articles into food or food simulants at least once. These 211 FCCs were checked against the inventory FCCs databases and EU regulatory lists. Only 25% of the detected FCCs are authorized by EU regulation for the manufacture of food contact materials. Furthermore, a quarter of authorized FCCs exceeded the specific migration limit (SML) at least once, while one-third (53) of non-authorised FCCs exceeded the threshold value of 10 μg/kg. Overall, evidence on FCCs migration across the PE food packaging lifecycle is incomplete, especially at the reprocessing stage. Considering the EU's commitment to increase packaging recycling, a better understanding and monitoring of PE food packaging quality from a chemical perspective across the entire lifecycle will enable the transition towards a sustainable plastics value chain.

Combination of Structure Databases, In Silico Fragmentation, and MS/MS Libraries for Untargeted Screening of Non-Volatile Migrants from Recycled High-Density Polyethylene Milk Bottles

Chemical contamination is one of the major obstacles for mechanical recycling of plastics. In this article, we built and open-sourced an in-house MS/MS library containing more than 500 plastic-related chemicals and developed mspcompiler, an R package, for the compilation of various libraries. We then proposed a workflow to process untargeted screening data acquired by liquid chromatography high-resolution mass spectrometry. These tools were subsequently employed to data originating from recycled high-density polyethylene (rHDPE) obtained from milk bottles. A total of 83 compounds were identified, with 66 easily annotated by making use of our in-house MS/MS libraries and the mspcompiler R package. In silico fragmentation combined with data obtained from gas chromatography-mass spectrometry and lists of chemicals related to plastics were used to identify those remaining unknown. A pseudo-multiple reaction monitoring method was also applied to sensitively target and screen the identified chemicals in the samples. Quantification results demonstrated that a good sorting of postconsumer materials and a better recycling technology may be necessary for food contact applications. Removal or reduction of non-volatile substances, such as octocrylene and 2-ethylhexyl-4-methoxycinnamate, is still challenging but vital for the safe use of rHDPE as food contact materials.

One-dimensional and comprehensive two-dimensional gas chromatographic approaches for the characterization of post-consumer recycled plastic materials

In September 2022, the European Commission published its new regulation on recycled plastic materials for food contact. It allows newly developed, non-authorized technologies and approaches, or so-called novel technologies, to be deployed in the field to generate the data needed for establishing regulatory and/or fit for purpose processes. The data shall be generated by using suitable methods, but the regulation does not give a more detailed description on those. In this study, commercially purchased buckets made of post-consumer recycled polypropylene were screened, using a number of different analytical approaches. Sample preparation methods, analysis techniques, and the data and information generated were compared. The results clearly demonstrate the need for a detailed characterization of such materials and the advantages and disadvantages of the analysis using conventional gas chromatography with flame ionization detection and mass spectrometery as well as two-dimensional comprehensive gas chromatography with time of flight mass spectrometry.

Recycling of polypropylene by supercritical carbon dioxide for extraction of contaminants from beverage cups. A comparison with polyethylene terephthalate and polylactic acid

BACKGROUND

EU policies towards a circular economy address plastic packaging as one of the significant concerns and sets ambitious recycling targets. Polyolefins (POs) cannot be recycled for food contact using conventional polyethylene terephthalate (PET) recycling approaches. Thermal degradation prevents the use of high temperatures and, consequently, decontamination of POs may be insufficient when using lower temperatures. Polypropylene (PP) beverage cups were decontaminated using supercritical fluid extraction with carbon dioxide (scCO₂ ). Decontamination efficiencies (DEs) of selected markers were determined in challenge tests following European Food Safety Authority guidelines. The effects of time (10-60 min) for PET, polylactic acid (PLA), and PP and temperature (60-80 °C) for PP were studied at constant pressure. The physical properties, sensorial properties, and overall migration of treated scCO₂ PP were analysed and compared with virgin PP.

RESULTS

PP showed the highest average DE, and PET the lowest, for all the surrogates and in all time conditions. A relative increase in the DE with the increase in process time, particularly for PET and to some extent for PLA, was seen. For PP, no significant impact of time and temperature was observed under the conditions tested. The DE of volatile surrogates was higher than that of semi-volatiles. Results indicate that the scCO₂ treatment did not affect the physical and sensorial properties, nor the overall migration of PP, although it contributes to a considerable reduction in extractable n < C24 alkanes.

CONCLUSIONS

Results indicate that scCO₂ can be used to decontaminate post-consumption PP beverage cups with higher DEs than those for PET and PLA, applying mild processing conditions. © 2022 Society of Chemical Industry.

Machine learning directed discrimination of virgin and recycled poly(ethylene terephthalate) based on non-targeted analysis of volatile organic compounds

The use of non-decontaminated recycled poly(ethylene terephthalate) (PET) in food packages arouses consumer safety concerns, and thus is a major obstacle hindering PET bottle-to-bottle recycling in many developing regions. Herein, machine learning (ML) algorithms were employed for the discrimination of 127 batches of virgin PET and recycled PET (rPET) samples based on 1247 volatile organic compounds (VOCs) tentatively identified by headspace solid-phase microextraction comprehensive two-dimensional gas chromatography quadrupole-time-of-flight mass spectrometry. 100% prediction accuracy was achieved for PET discrimination using random forest (RF) and support vector machine (SVM) algorithms. The features of VOCs bearing high variable contributions to the RF prediction performance characterized by mean decrease Gini and variable importance were summarized as high occurrence rate, dominant appearance and distinct instrument response. Further, RF and SVM were employed for PET discrimination using the simplified input datasets composed of 62 VOCs with the highest contributions to the RF prediction performance derived by the AUCRF algorithm, by which over 99% prediction accuracy was achieved. Our results demonstrated ML algorithms were reliable and powerful to address PET adulteration and were beneficial to boost food-contact applications of rPET bottles.

MEX 3D Printed HDPE/TiO2 Nanocomposites Physical and Mechanical Properties Investigation

Aiming to develop more robust, mechanically advanced, Fused Filament Fabrication (FFF) materials, High-Density Polyethylene (HDPE) nanocomposites were developed in the current research work. Titanium Dioxide (TiO2) was selected as filler to be incorporated into the HDPE matrix in concentration steps of 0.5, 2.5, 5, and 10 wt.%. 3D printing nanocomposite filaments were extruded in ~1.75 mm diameter and used to 3D print and test tensile and flexion specimens according to international standards. Reported results indicate that the filler contributes to increasing the mechanical strength of the virgin HDPE at certain filler and filler type concentrations; with the highest values reported to be 37.8% higher in tensile strength with HDPE/TiO2 10 wt.%. Morphological and thermal characterization was performed utilizing Scanning Electron Microscopy (SEM), Raman, Thermogravimetric Analysis (TGA), and Differential Scanning Calorimetry (DSC), while the results were correlated with the available literature.

Electrochemical Control of Biofilm Formation and Approaches to Biofilm Removal

This review deals with microbial adhesion to metal-based surfaces and the subsequent biofilm formation, showing that both processes are a serious problem in the food industry, where pathogenic microorganisms released from the biofilm structure may pollute food and related material during their production. Biofilm exhibits an increased resistance toward sanitizers and disinfectants, which complicates the removal or inactivation of microorganisms in these products. In the existing traditional techniques and modern approaches for clean-in-place, electrochemical biofilm control offers promising technology, where surface properties or the reactions taking place on the surface are controlled to delay or prevent cell attachment or to remove microbial cells from the surface. In this overview, biofilm characterization, the classification of bacteria-forming biofilms, the influence of environmental conditions for bacterial attachment to material surfaces, and the evaluation of the role of biofilm morphology are described in detail. Health aspects, biofilm control methods in the food industry, and conventional approaches to biofilm removal are included as well, in order to consider the possibilities and limitations of various electrochemical approaches to biofilm control with respect to potential applications in the food industry.

Safety assessment of the process Cajas y Palets en una Economia Circular (CAPEC), used to recycle high-density polyethylene and polypropylene crates for use as food contact materials

The EFSA Panel on Food Contact Materials, Enzymes and Processing Aids (CEP) assessed the safety of the recycling process Cajas y Palets en una Economia Circular (CAPEC) (EU register number RECYC242). The input consists of crates made of high-density polyethylene (HDPE) or polypropylene (PP) originating from closed and controlled product loops for the packaging of whole fruits and vegetables. Flakes or pellets are produced that will be used by manufacturers of new crates for food contact. The Panel considered that the management system put in place to ensure compliance of the origin of the input with Commission Regulation (EC) No 282/2008 and to provide full traceability from input to final product is the critical process step. It concluded that the input of the process CAPEC originates from product loops which are in closed and controlled chains designed to ensure that only materials and articles that have been intended for food contact are used and that contamination can be ruled out when run under the conditions described by the applicant. The recycling process CAPEC is therefore suitable to produce recycled HDPE and PP crates intended to be used in contact with fruits and vegetables.

Safety assessment of the process Kunststof Recycling Nederland (KRN), used to recycle high density polyethylene box pallets for use as food contact materials

The EFSA Panel on Food Contact Materials, Enzymes and Processing Aids (CEP) assessed the safety of the recycling process Kunststof Recycling Nederland (KRN) (EU register number RECYC251). The input consists of box pallets made of high-density polyethylene (HDPE) originating from a closed and controlled product loop for packaging of meat. Flakes are used to produce new box pallets for food contact. The Panel considered that the management system put in place to provide full traceability from the input to the final product and to ensure compliance of the origin of the input with Commission Regulation (EC) No 282/2008 is critical. According to the applicant, the input of the process KRN originates from a product loop which is in closed and controlled chain, designed to ensure that only materials and articles that have been intended for food contact are used and that contamination can be ruled out when run under the conditions described by the applicant. The Panel concluded that the recycling process KRN is suitable to produce recycled HDPE box pallets intended to be used in contact with refrigerated or frozen, packed or unpacked meat.

The Effects of Chemical and Mechanical Stresses on Bacillus cereus and Pseudomonas fluorescens Single- and Dual-Species Biofilm Removal

Biofilm control is mainly based on chemical disinfection, without a clear understanding of the role of the biocides and process conditions on biofilm removal. This study aims to understand the effects of a biocide (benzyldimethyldodecyl ammonium chloride-BDMDAC) and mechanical treatment (an increase of shear stress -τw) on single- and dual-species biofilms formed by Bacillus cereus and Pseudomonas fluorescens on high-density polyethene (HDPE). BDMDAC effects were initially assessed on bacterial physicochemical properties and initial adhesion ability. Then, mature biofilms were formed on a rotating cylinder reactor (RCR) for 7 days to assess the effects of chemical and mechanical treatments, and the combination of both on biofilm removal. The results demonstrated that the initial adhesion does not predict the formation of mature biofilms. It was observed that the dual-species biofilms were the most susceptible to BDMDAC exposure. The exposure to increasing τw emphasised the mechanical stability of biofilms, as lower values of τw&nbsp;(1.66 Pa) caused high biofilm erosion and higher τw values (17.7 Pa) seem to compress the remaining biofilm. In general, the combination of BDMDAC and the mechanical treatment was synergic in increasing biofilm removal. However, these were insufficient to cause total biofilm removal (100%; an average standard deviation of 11% for the method accuracy should be considered) from HDPE.

Sustainable Additive Manufacturing: Mechanical Response of High-Density Polyethylene over Multiple Recycling Processes

Polymer recycling is nowadays in high-demand due to an increase in polymers demand and production. Recycling of such materials is mostly a thermomechanical process that modifies their overall mechanical behavior. The present research work focuses on the recyclability of high-density polyethylene (HDPE), one of the most recycled materials globally, for use in additive manufacturing (AM). A thorough investigation was carried out to determine the effect of the continuous recycling on mechanical, structural, and thermal responses of HDPE polymer via a process that isolates the thermomechanical treatment from other parameters such as aging, contamination, etc. Fused filament fabrication (FFF) specimens were produced from virgin and recycled materials and were experimentally tested and evaluated in tension, flexion, impact, and micro-hardness. A thorough thermal and morphological analysis was also performed. The overall results of this study show that the mechanical properties of the recycled HDPE polymer were generally improved over the recycling repetitions for a certain number of recycling steps, making the HDPE recycling a viable option for circular use. Repetitions two to five had the optimum overall mechanical behavior, indicating a significant positive impact of the HDPE polymer recycling aside from the environmental one.

Technical Limits in Circularity for Plastic Packages

The current Dutch recycling value chain for plastic packaging waste (PPW) has not reached its full circularity potential, as is apparent from two Circular Performance Indicators (CPIs): net packaging recycling rate and average polymer purity of the recycled plastics. The performance of the recycling value chain can be optimised at four stages: packaging design, collection, sorting, and recycling. This study explores the maximally achievable performance of a circular PPW recycling value chain, in case all stakeholders would implement the required radical improvement measures in a concerted action. The effects of the measures were modelled with material flow analysis. For such a utopic scenario, a net plastic packaging recycling rate of 72% can be attained and the produced recycled plastics will have an average polymeric purity of 97%. This is substantially more than the net packaging recycling rate of 37% for 2017 and will exceed the EU target of 50% for 2025. In such an ideal circular value chain more recycled plastics are produced for more demanding applications, such as food packaging, compared to the current recycling value chain. However, all stakeholders would need to implement drastic and coordinated changes, signifying unprecedented investments, to achieve this optimal circular PPW recycling value chain.

Total Life Cycle of Polypropylene Products: Reducing Environmental Impacts in the Manufacturing Phase

This paper assesses the environmental burdens of a polypropylene product throughout the product’s life cycle, especially focusing on the injection-moulding stage. The complete life cycle model of the polypropylene product has been developed from the raw material extraction and production phase through its usage to the end-of-life stage with the help of the life cycle assessment method. To find the answers to the posed problems, different impacts were analysed by GaBi 8.0 software. The analysis lasted from the cradle to the grave, expanding the analysis of the looping method. The aim of the research was to determine the energy and material resources, emissions, and environmental impact indicators. Basically, the article tried to answer three questions: (1) How can we optimize the production phase for the looping method? (2) Which materials and streams are recyclable in the design of the production process? (3) What is the relationship between life cycle stages and total life cycle of the product? As we inspect the life cycle of the product, the load on the environment was distributed as follows: 91% in the production phase, 3% in the use phase, and 6% in the end-of-life phase. The results of the research can be used to develop technologies, especially the injection-moulding process, with a lower environmental impact.

Rapid classification of virgin and recycled EPS containers by Fourier transform infrared spectroscopy and chemometrics

A rapid and sensitive method for classification of virgin and recycled expanded polystyrene (EPS) food containers was developed using Fourier transform infrared spectroscopy (FTIR) and chemometrics. This method includes preparing a transparent film by dissolution, examining by FTIR and developing classification models. The degradation of EPS containers occurring during the recycling process was reflected by the carbonyl region of the infrared spectrum which was used as variables for multivariate data analysis. PCA was used to reduce the data dimension and view the sample similarities. Soft independent modelling of class analogy (SIMCA), partial least squares-discrimination analysis (PLS-DA) and linear discrimination analysis (LDA) were applied to construct three classification models. The best discrimination results were obtained by an LDA model, with all samples correctly classified. PLS-DA and SIMCA could not classify the recycled EPS samples with low levels of adulteration. When applying this method to commercially available EPS containers, about 45% of samples were shown to contain recycled polystyrene resins. It is concluded that the carbonyl region of the infrared spectra coupled with chemometrics could be a powerful tool for the classification of virgin and recycled EPS food containers.

Safety assessment of the process 'Morssinkhof Plastics', used to recycle high-density polyethylene and polypropylene crates for use as food contact materials

This scientific opinion of the EFSA Panel on Food Contact Materials, Enzymes, Flavourings and Processing Aids (CEF Panel) deals with the safety evaluation of the recycling process 'Morssinkhof Plastics', EU register No RECYC0142. The input consists of crates, boxes, trays, pallets and containers, hereafter termed 'crates', used in food contact, made of high-density polyethylene (HDPE) or polypropylene (PP). It comprises unused damaged crates, prewashed used crates and parts of crates originating from closed and controlled product loops. The process separates crates by material type and food type (fruit, vegetables and prepacked meat vs unpacked meat). Flakes from recycled HDPE or PP are produced that will be used by customers to manufacture new crates for food contact. The Panel considered that the management system put in place to ensure compliance of the origin of the input with Commission Regulation (EC) No 282/2008 and to provide full traceability from input to final product is the critical process step. It concluded that the input of the process 'Morssinkhof Plastics' originates from product loops which are in closed and controlled chains designed to ensure that only materials and articles which have been intended for food contact are used and that any contamination can be ruled out when run under the conditions described by the applicant. The recycling process 'Morssinkhof Plastics' is, therefore, able to produce recycled HDPE and PP suitable for manufacturing HDPE and PP crates intended to be used in contact with dry food, fruits and vegetables, prepacked and unpacked meat. The use of regrind from 'external' recyclers only based on private agreements, does not give reassurance to fall under the scope of Art. 4 c (i) of Commission Regulation (EC) No 282/2008 and is excluded from the present evaluation.

Polímeros reciclados para contato com alimentos

Os resíduos sólidos urbanos (RSUs) são atualmente um dos maiores problemas ambientais, por serem gerados em grande quantidade e ocuparem extensos espaços por um longo período, resultando na diminuição do tempo de vida útil dos aterros sanitários. Os polímeros constituem um grande percentual da composição do RSUs, sendo que as embalagens plásticas contribuem com maior volume e massa. Apesar da reciclagem de polímeros estarem se consolidando no Brasil, graças ao seu mercado ascendente e promissor, existem ainda restrições quanto a sua utilização em contato com alimentos devido aos eventuais processos de migração de contaminantes que podem ocorrer da resina reciclada para o alimento. Por outro lado, dados recentes do setor indicam que a maior parte do consumo de resina virgem é destinada, justamente, para o mercado de embalagens alimentícias. Assim, o desenvolvimento e o gerenciamento de tecnologias que possibilitem o retorno destes materiais a sua aplicação original é de grande importância para sociedade contemporânea. Em um panorama geral, este trabalho aborda as exigências e limitações do uso de polímeros reciclados para contato com alimentos.