European survey on post-consumer poly(ethylene terephthalate) (PET) materials to determine contamination levels and maximum consumer exposure from food packages made from recycled PET

Strategies to enhance the circularity of non-bottle PET packaging waste based on a detailed material characterisation

The compositions of Dutch lightweight packaging waste (LWP) and sorted products named "PET (Polyethylene terephthalate) trays" have been determined on object level. Additionally, the PET trays from both waste types were sorted in 16 categories representing their packaging use and material build-up. The material composition of at least 10 representative trays from each category was determined with chemical and thermal analysis, based on which the average material composition per category was established. Based on this data the average material composition of sorted PET tray products was approximated. The recyclability of the various categories of PET trays was assessed based on their material build-up. The most ubiquitous PET trays in Dutch LWP and sorted products were only found to be suitable to produce opaque recycled PET with mechanical recycling processes. Whereas only some more uncommon PET trays can be used to produce transparent recycled PET with mechanical recycling processes. Depolymerisation is deemed to be a more appropriate recycling process that will allow the production of transparent food-grade recycled PET.

Scientific Guidance on the criteria for the evaluation and on the preparation of applications for the safety assessment of post-consumer mechanical PET recycling processes intended to be used for manufacture of materials and articles in contact with food

In the context of entry into force of Regulation (EU) 2022/1616, EFSA updated the scientific guidance to assist applicants in the preparation of applications for the authorisation or for the modification of an existing authorisation of a 'post-consumer mechanical PET' recycling process (as defined in Annex I of Regulation (EU) 2022/1616) intended to be used for manufacturing materials and articles intended to come into contact with food. This Guidance describes the evaluation criteria and the scientific evaluation approach that EFSA will apply to assess the decontamination capability of recycling processes, as well as the information required to be included in an application dossier. The principle of the scientific evaluation approach is to apply the decontamination efficiency of a recycling process, obtained from a challenge test with surrogate contaminants, to a reference contamination level for post-consumer PET, set at 3 mg/kg PET for a contaminant resulting from possible misuse. The resulting residual concentration of each surrogate in recycled PET is then compared to a modelled concentration in PET that is calculated using generally recognised conservative migration models, such that the related migration does not give rise to a dietary exposure exceeding 0.0025 μg/kg body weight (bw) per day. This is the lowest threshold for toxicological concern (TTC) value, i.e. for potential genotoxicity, below which the risk to human health would be negligible. The information to be provided in the applications relates to: the recycling process (i.e. collection and pre-processing of the input, decontamination process, post-processing and intended use); the determination of the decontamination efficiency by the challenge test; the self-evaluation of the recycling process. On the basis of the submitted data, EFSA will assess the safety of the mechanical PET recycling process.

Evaluation of chemicals leached from PET and recycled PET containers into beverages

The use of recycled polyethylene terephthalate (rPET) containers, a recent shift in the beverage industry, poses new potential human health concerns including contamination from the original container; use of additives, detergents, and catalysts during recycling; and improper recycling practices. The purpose of this analysis was to evaluate available data regarding: (1) chemicals leached from PET and rPET in bottle form; (2) concentration of these chemicals; and (3) trends between rPET percent and concentration of chemicals leached. This analysis identified 211 scientific articles related to recycled plastic and leachables. Three articles met the inclusion criteria: (1) plastic was in bottle form; (2) plastic was made of PET or rPET; and (3) the study analyzed both PET and rPET using the same methods. This evaluation demonstrated that only nine compounds - benzene, styrene, acetaldehyde, 2-methyl-1,3-dioxolane, furan, bisphenol A (BPA), 2-buta-none, acetone, and limonene - have been studied. Notably, the leachable concentration of benzene, styrene, and BPA increased as the percent of recycled content increased from 0 to 100%. However, 2-methyl-1,3-dioxolane and furan implied a reverse trend, where the leachable concentration decreased as the percent of recycled content increased from 0 to 100%. The concentrations of 2-butanone, acetone, and limonene did not follow any suggested trend. Evidently, recycling PET can lead to changes in the leachables profile. This analysis further identified key areas of research, including testing a variety of liquid types, that need to be addressed to adequately conduct a human health risk assessment.

Occurrence and prioritization of non-volatile substances in recycled PET flakes produced in China

Recycled PET (rPET) is gaining popularity for use in the production of new food contact materials (FCMs) under the context of circular economy. However, the limited information on contaminants in rPET from China and concerns about their potential risk are major obstacles to their use in FCM in China. Fifty-five non-volatile compounds were tentatively identified in 126 batches of hot-washed rPET flakes aimed for food packaging applications in China. Although the 55 substances are not necessarily migratable and may not end up in the contacting media, their presence indicates a need for proper management and control across the value chain. For this reason, the 55 substances prioritized on the basis of level of concerns and in-silico genotoxicity profiler. Among them, dimethoxyethyl phthalate, dibutyl phthalate, bis(2-ethylhexyl) phthalate were classified as level V substances, and Michler's ketone and 4-nitrophenol were both categorized as level V substances and had the genotoxic structure alert, while 2,4,5-trimethylaniline was specified with genotoxic structure alert. The above substances have high priority and may pose a potential risk to human health, therefore special attention should be paid to their migration from rPET. Aside from providing valuable information on non-volatile contaminants present in hot-washed rPET flakes coming from China, this article proposed a prioritization workflow that can be of great help to identify priority substances deserving special attention across the value chain.

Occurrence of volatile contaminants in recycled poly(ethylene terephthalate) by HS-SPME-GC×GC-QTOF-MS combined with chemometrics for authenticity assessment of geographical recycling regions

A comparison was performed on various methods detecting the volatile contaminants (VCs) in recycled poly(ethylene terephthalate) (rPET) flakes, the results demonstrated that head-space solid phase micro-extraction combined with comprehensive two-dimensional gas chromatograph-tandem quadrupole-time-of-flight mass spectrometry (HS-SPME-GC×GC-QTOF-MS) was a sensitive, effective, accurate method, and successfully applied to analyze 57 rPET flakes collected from different recycling plants in China. A total of 212 VCs were tentatively identified, and the possible source were associated with plastic, food, and cosmetics. 45 VCs are classified as high-priority compounds with toxicity level IV or V and may pose a risk to human health. Combined chemometrics for further analysis revealed that significant differences among these three geographical recycling regions. 6, 7, and 6 volatile markers were chosen based on VIP values and S-plot among plant1 plant 2 and plant 3, respectively. The markers differed significantly between recycled rPET samples in three geographical recycling regions based on chemometrics analysis. The initial classification rate and cross-validation accuracy were 100% on the identified VCs. These significant differences demonstrate that a systematic study is needed to obtain a comprehensive data on the contamination of rPET for food contact applications in China.

Determination of potential volatile compounds in polyethylene terephthalate (PET) bottles and their short- and long-term migration into food simulants and soft drink

Head space (HS)-GC-MS was used to analyze possible migration of volatile compounds from polyethylene terephthalate (PET) bottles for soft drinks, and a total of six compounds were identified. Next, a rapid, simple, and accurate simultaneous method was established using purge-and-trap (PT)-GC-MS, to quantify their amounts in the liquid contents after short- and long-term storage in PET bottles. Starting with brand-new PET bottles, the maximum migration of 2-methyl-1,3-dioxolane into distilled water and 50 % aqueous ethanol after 2 years at 25 °C were 2.3 and 19 ng/mL, respectively. In commercially available bottled mineral water sold inside and outside Japan, we were able to detect 2-methyl-1,3-dioxolane in the same way. While nonanal was also detected in some products, 2-methyl-1,3-dioxolane was confirmed as the main volatile compound. Finally, the human exposure to 2-methyl-1,3-dioxolane was estimated based on the per capita intake of soft drinks in Japan and the migration amount in this study.

Mechanical recyclability of biodegradable polymers used for food packaging: case study of polyhydroxybutyrate-co-valerate (PHBV) plastic

For the purpose of mechanical recycling for food contact applications, decontamination of polyhydroxybutyrate-co-valerate (PHBV) plastic was performed under different temperatures and time conditions. As expected, increasing the decontamination temperature and duration increased the decontamination efficiency, but also the degradation of the polymer. The combination 160 °C/6 h was selected as the optimal conditions that maximize contaminants removal while minimizing polymer degradation. Then the safety of the recycled PHBV under these conditions was assessed, in accordance with EFSA regulation based on bottle-to-bottle PET recycling. Decontamination of low molecular weight molecules such as toluene, chlorobenzene, and methyl salicylate was nearly complete with residual concentrations below the modeled concentrations allowed in the polymer when the adult scenario is considered. However, the higher molecular weight and lower volatility molecules exhibited acceptable decontamination efficiencies, but their residual concentrations in the polymer exceeded the maximum concentrations of no concern. The presence of these molecules allows the use of nearly 21% recycled PHBV in the new materials to meet safety criteria. It is important to keep in mind that this work, never done before, is a preliminary work on mechanical recycling of PHBV, mainly based on extrapolation of PET conditions and regulations. Much more research needs to be done to improve the decontamination process, the barrier properties of PHBV or to think about a short recycling line for PHBV.

Packaging Weight, Filling Ratio and Filling Efficiency of Yogurt and Relevant Packagings Depending on Commercial Packaging Design, Material, Packaging Type and Filling Quantity

Yogurt is a diverse dairy product category. It is available in different packaging designs made of different materials. To identify potential for improvement for these packagings, a better understanding about used materials and packaging efficiencies is necessary. For this study, 150 dairy products and some yogurt relevant desserts were bought from various supermarkets, street markets and discounters in the Munich region (Germany) in spring 2022. Commercial types of packaging are cups, buckets, pouches, bottles, glass packagings and bricks. The filling ratio of most packagings is above 70%, the rest of the volume is headspace. Poly(1-methylethylene) (PP) and poly(1-phenylethene) (PS) dominate as main materials for the different types of packaging. For bottle packagings, poly(ethylene terephthalate) (PET) and polyethene high-density (PE-HD) are used. Interestingly, poly(lactic acid) (PLA) is not found. Closures (caps) are responsible for 5 to 30% of the total packaging weight. Typical filling efficiencies are 20 to 40 g food product packaged in one gram of packaging material. For glass packagings, the values are 1.5 to 2 g food product packaged in one gram of packaging material. Therefore, plastic packaging results in an at least ten-times lower packaging use per unit of food, at single use packagings. With increasing product weights, we observe a tendency towards higher packaging efficiencies. By using paper/carton wrapping at cups, plastic use is reduced for the whole packaging.

Deodorization of post-consumer plastic waste fractions: A comparison of different washing media

An important impediment to the acceptance of recyclates into a broader market is their unwanted odor after reprocessing. Different types of washing procedures are already in place, but fundamental insights into the deodorization efficiencies of different washing media are still relatively scarce. Therefore, in this study, the deodorization efficiencies of different types of plastics after washing with different media were determined via gas chromatography and mass spectrometry analysis. A total of 169 compounds subdivided into various chemical classes, such as alkanes, terpenes, and oxygenated compounds, were detected across all packaging types. Around 60 compounds were detected on plastic bottles, and around 40 were detected on trays and films. Owing to the differences in physicochemical properties of odor compounds, different deodorization efficiencies were obtained with different washing media. Water and caustic soda were significantly more efficient for poly(ethylene terephthalate) bottles with deodorization efficiencies up to 80%, whereas for polyethylene (PE) and polypropylene bottles, the washing media were relatively inefficient (around 30-40%). Adding a detergent or an organic solvent could increase deodorization efficiencies by up to 70-90% for these packaging types. A similar trend was observed for PE films having deodorization efficiencies in the range of 40-50% when washing with water or caustic soda and around 70-80% when a detergent was added. Polystyrene trays were most effectively deodorized with a detergent, achieving efficiencies up to 67%. Hence, this study shows that optimal washing processes should be tailored to specific packaging types to further improve deodorization and to eventually be able to meet ambitious European recycling targets.

Recycling of Post-Consumer Packaging Materials into New Food Packaging Applications—Critical Review of the European Approach and Future Perspectives

The European strategy for plastics, as part of the EU’s circular economy action plan, should support the reduction in plastic waste. One key element in this action plan is the improvement of the economics and quality of recycled plastics. In addition, an important goal is that by 2030, all plastics packaging placed on the EU market must either be reusable or can be recycled in a cost-effective manner. This means that, at the end, a closed-loop recycling of food packaging materials should be established. However, the use of recyclates must not result in less severe preventive consumer protection of food packaging materials. This may lead to a conservative evaluation of authorities on post-consumer recyclates in food packaging applications. On the other hand, over-conservatism might over-protect the consumer and generate insurmountable barriers to the application of post-consumer recyclates for food packaging and, hence, counteract the targets of circular economy. The objective of this review is to provide an insight into the evaluation of post-consumer recyclates applied in direct contact to food. Safety assessment criteria as developed by the European Food Safety Authority EFSA will be presented, explained, and critically discussed.

Safety Evaluation of Polyethylene Terephthalate Chemical Recycling Processes

Polyethylene terephthalate (PET) is one of the main packaging materials for beverage bottles. Even if this polymer is good to recycle, mechanical recycling processes need a well-sorted input fraction. For less-sorted PET packaging, or even non-food input sources, chemical recycling seems to be a solution to increase PET recycling. For post-consumer recyclates in packaging applications, it is essential that the safety of the recyclates is guaranteed, and the consumers’ health protected. For mechanical recycling processes, evaluation criteria are already established. For chemical recycling processes, however, such evaluation criteria are only roughly available. This study evaluated the safety of the chemical recycling process similar to the approach of the European Food Safety Authority (EFSA). However, due to the lack of information about the contamination level of the input materials for the chemical recycling process, the evaluation was adapted. In addition, the evaluation should be performed separately for the depolymerisation and for the repolymerisation steps. However, due to the high cleaning efficiencies of both steps, the evaluation can focus on the repolymerisation. This simplifies the assessment of the chemical recycling processes considerably.

Identification of Potential Migrants in Polyethylene Terephthalate Samples of Ecuadorian Market

Polyethylene terephthalate (PET) is the plastic packaging material most widely used to produce bottles intended for contact with food and beverages. However, PET is not inert, and therefore, some chemical compounds present in PET could migrate to food or beverages in contact, leading to safety issues. To evaluate the safety of PET samples, the identification of potential migrants is required. In this work, eight PET samples obtained from the Ecuadorian market at different phases of processing were studied using a well-known methodology based on a solvent extraction followed by gas chromatography–mass spectrometry analysis and overall migration test. Several chemical compounds were identified and categorized as lubricants (carboxylic acids with chain length of C12 to C18), plasticizers (triethyl phosphate, diethyl phthalate), thermal degradation products (p-xylene, benzaldehyde, benzoic acid), antioxidant degradation products (from Irgafos 168 and Irganox), and recycling indicator compounds (limonene, benzophenone, alkanes, and aldehydes). Additionally, overall migration experiments were performed in PET bottles, resulting in values lower than the overall migration limit (10 mg/dm²); however, the presence of some compounds identified in the samples could be related to contamination during manufacturing or to the use of recycled PET-contaminated flakes. In this context, the results obtained in this study could be of great significance to the safety evaluation of PET samples in Ecuador and would allow analyzing the PET recycling processes and avoiding contamination by PET flakes from nonfood containers.

Circularity Study on PET Bottle-To-Bottle Recycling

With the European Green Deal, the importance of recycled products and materials has increased. Specifically, for PET bottles, a high content of recycled material (rPET) is demanded by the industry and consumers. This study was carried out in a lab environment replicating real-life industrial processes, to investigate the possible impacts on rPET quality over eleven recycling loops, aiming to use high amounts of rPET repetitively. A cycle included extrusion, solid state polycondensation (SSP), a second extrusion to simulate bottle production, hot wash and a drying step. 75% rPET and 25% virgin PET were extruded in eleven cycles to simulate a recycling and production process. Samples underwent chemical, physical and biological analysis. The quality of the rPET material was not adversely affected. Parameters such as coloring, intrinsic viscosity, concentration of critical chemicals and presence of mutagenic contaminants could be positively assessed. The quality of the produced material was likely influenced by the input material’s high standard. A closed loop PET bottle recycling process using an rPET content of up to 75% was possible when following the proposed process, indicating that this level of recycled content can be maintained indefinitely without compromising quality.

Strategic Possibility Routes of Recycled PET

The polyethylene terephthalate (PET) application has many challenges and potential due to its sustainability. The conventional PET degradation was developed for several technologies to get higher yield products of ethylene glycol, bis(2-hydroxyethyl terephthalate) and terephthalic acid. The chemical recycling of PET is reviewed, such as pyrolysis, hydrolysis, methanolysis, glycolysis, ionic-liquid, phase-transfer catalysis and combination of glycolysis-hydrolysis, glycolysis-methanolysis and methanolysis-hydrolysis. Furthermore, the reaction kinetics and reaction conditions were investigated both theoretically and experimentally. The recycling of PET is to solve environmental problems and find another source of raw material for petrochemical products and energy.

Contamination Levels in Recollected PET Bottles from Non-Food Applications and their Impact on the Safety of Recycled PET for Food Contact

PET beverage bottles have been recycled and safely reprocessed into new food contact packaging applications for over two decades. During recollection of post-consumer PET beverage bottles, PET containers from non-food products are inevitably co-collected and thereby enter the PET recycling feed stream. To explore the impact of this mixing on the safety-in-use of recycled PET (rPET) bottles, we determined the concentrations of post-consumer substances in PET containers used for a range of non-food product applications taken from the market. Based on the chemical nature and amounts of these post-consumer substances, we evaluated their potential carry-over into beverages filled in rPET bottles starting from different fractions of non-food PET in the recollection systems and taking worst-case cleaning efficiencies of super-clean recycling processes into account. On the basis of the Threshold of Toxicological Concern (TTC) concept and Cramer classification tools, we present a risk assessment for potential exposure of the consumer to the identified contaminants as well as unidentified, potentially genotoxic substances in beverages. As a result, a fraction of 5% non-food PET in the recycling feed stream, which is very likely to occur in the usual recollection systems, does not pose any risk to the consumer. Our data show that fractions of up to 20%, which may sporadically be contained in certain, local recollection systems, would also not raise a safety concern.

Non-intentionally added substances (NIAS) in recycled plastics

The demand for high quality recycled polymers in the European plastic industry is on the increase, likely due to the EU's Plastic Strategy intended to implement the circular economy model in this sector. The problem is that there is not enough recycled plastic in the market. In terms of volume, post-consumer plastic waste could be key to meet the current and future demand. Nevertheless, a high level of contamination originated during the product's life cycle restricts its use. The first step to change this must be identifying the undesired substances in post-consumer plastics and performing an effective risk assessment. The acquired knowledge will be fundamental for the development of innovative decontamination technologies. In this study, 134 substances including volatile and semi-volatile compounds have been identified in recycled LDPE and HDPE from domestic waste. Headspace and solvent extraction followed by GC/MS were used. The possible origin of each substance was studied. The main groups were additives, polymer and additives breakdown products, and contamination from external sources. The results suggest that recycled LDPE contains a broader number of additives and their degradation products. Some of them may cause safety concerns if reused in higher added value applications. Regarding recycled HDPE, the contaminants from the use phase are predominant creating problems such as intense odors. To reduce the number of undesired substances, it is proposed to narrow the variety of additives used in plastic manufacturing and to opt for separate waste collection systems to prevent cross-contamination with organic waste.

Odorant composition of post-consumer LDPE bags originating from different collection systems

The establishment of recycling systems aiming at high-quality recyclates from post-consumer plastic waste are essential to avoid the waste of resources. One main impediment for introducing recyclates into the market is their unwanted odor. For this reason, this study aimed at determining if the collection strategy affects the odor profile of post-consumer LDPE bags. Furthermore, the effect of hot water washing, inspired by the conventional mechanical recycling procedure, on the odor of post-consumer LDPE bags was screened. More than 60 odorants were detected in LDPE bags collected in a separate plastic fraction as well as in LDPE bags from the non-separated collection by means of gas chromatography-olfactometry, and 37 of them were unequivocally identified using two-dimensional gas chromatography-mass spectrometry/olfactometry. The sensory results revealed that the type of collection affects the overall odor intensity, the hedonic tone of the odor and the odor profile. Namely, cheesy and fecal smelling odorants were predominant in the waste that had not been separated at source, whereas odorants with earthy and moldy smells showed mostly higher intensity ratings in the waste separated at source. Short chain carboxylic acids, likely originating from microbial spoilage of organic waste, were found with higher dilution factors in the mixed fraction, and could, accordingly, contribute to the observed differences. Additionally, we could show that the hot washing procedure, applied to the LDPE sample from the separate collection system, significantly reduced the overall odor intensity from 8 to 6.3 (0-10 scale). However, the washed waste still showed high smell intensity ratings.

Sensor array for the detection of organic and inorganic contaminants in post-consumer recycled plastics for food contact

Post-consumer recycled (PCR) plastic material is made by collecting used plastic products (e.g., bottles and other plastic packaging materials) and reprocessing them into solid-state pellets or flakes. Plastic recycling has positive environmental benefits, but may also carry potential drawbacks due to unwanted organic and inorganic contaminants. These contaminants can migrate into food packaging made from these recycled plastic materials. The purpose of this research was to identify economically viable real-time monitoring technologies that can be used during the conversion of virgin and recycled resin feedstocks (i.e., various blends of virgin pellets and recycled solid-state pellet or mechanically ground flake) to final articles to ensure the safety, quality and sustainability of packaging feedstocks. Baseline analysis (validation) of real-time technologies was conducted using industry-standard practices for polymer analysis. The data yielded supervised predictive models developed by training sessions completed in a controlled laboratory setting. This technology can be employed to evaluate compliance and aid converters in commodity sourcing of resin without exceeding regulatory thresholds. Furthermore, this technology allowed for real-time decision and diversion strategies during the conversion of resin and flake to final articles or products to minimise the negative impact on human health and environmental exposure.

Screening of hormone-like activities in bottled waters available in Southern Spain using receptor-specific bioassays

Bottled water consumption is a putative source of human exposure to endocrine-disrupting chemicals (EDCs). Research has been conducted on the presence of chemicals with estrogen-like activity in bottled waters and on their estrogenicity, but few data are available on the presence of hormonal activities associated with other nuclear receptors (NRs). The aim of this study was to determine the presence of endocrine activities dependent on the activation of human estrogen receptor alpha (hERa) and/or androgen receptor (hAR) in water in glass or plastic bottles sold to consumers in Southern Spain. Hormone-like activities were evaluated in 29 bottled waters using receptor-specific bioassays based on reporter gene expression in PALM cells [(anti-)androgenicity] and cell proliferation assessment in MCF-7 cells [(anti-)estrogenicity] after optimized solid phase extraction (SPE). All of the water samples analyzed showed hormonal activity. This was estrogenic in 79.3% and anti-estrogenic in 37.9% of samples and was androgenic in 27.5% and anti-androgenic in 41.3%, with mean concentrations per liter of 0.113pM 17β-estradiol (E2) equivalent units (E2Eq), 11.01pM anti-estrogen (ICI 182780) equivalent units (ICI 182780Eq), 0.33pM methyltrienolone (R1881) equivalent units (R1881Eq), and 0.18nM procymidone equivalent units (ProcEq). Bottled water consumption contributes to EDC exposure. Hormone-like activities observed in waters from both plastic and glass bottles suggest that plastic packaging is not the sole source of contamination and that the source of the water and bottling process may play a role, among other factors. Further research is warranted on the cumulative effects of long-term exposure to low doses of EDCs.

Decontamination efficiency of a new post-consumer poly(ethylene terephthalate) (PET) recycling concept

The aim of the study was to investigate and evaluate the cleaning efficiency of a new recycling concept for post-consumer poly(ethylene terephthalate) (PET). The so-called Flake To Resin (FTR) recycling process produces PET pellets or preforms from conventionally recycled PET flakes for the application in new PET packaging in direct food contact. The investigated process can be considered as 'super-clean' recycling process and was developed to introduce conventional recycled post-consumer (PCR) PET flakes up to an amount of 50% into the pellet and preform production. Within the study the cleaning efficiency of the investigated FTR process was determined by a challenge test. The experimental results obtained from three challenge tests with different input concentrations of the surrogates and different amounts of post-consumer PET flakes show that all applied surrogates are very efficiently removed by the investigated recycling process. The cleaning efficiencies for all surrogates are above 99.9%. In the final product of the process no surrogates could be determined above the detection limits (0.5 mg kg(-1)) even if the initial concentrations were in the percentage range. From a migrational point the final product, which are either PET pellets or preforms, was similar to virgin PET. Only the PET typical substances acetaldehyde and ethylene glycol had slightly higher concentrations than found in a conventional PET virgin sample used as reference. The generally accepted migration limit of 10 microg kg(-1) for the surrogates in the final products of the challenge tests is established for all kinds of foodstuffs.

Migration of organic compounds from a multilayer plastic–paper material intended for food packaging

This paper deals with the study of the kinetic migration of a series of organic compounds representative of potential contaminants in packaging materials and used as surrogates (o-xylene, acetophenone, dodecane, naphthalene, 2,3,4-trichloroanisole, benzophenone, isomeric mix of diisopropylnaphthalene, diisobutyl phthalate and methyl stearate). Migration to one side of a solid simulant, Tenax, also referred to as MPPO (modified polyphenylene oxide), was investigated in this study. One spiked sample of multilayer material was used to optimise the extraction procedures for the multilayer paper-based material and the Tenax as well as to perform kinetic migration studies. Three sequential extractions using ethanol were necessary for the strips of the multilayer material but only one extraction was necessary for the solid simulant to obtain >70% recovery of the surrogates. These results enabled us to specify the extraction requirements of the multilayer sample and the solid simulant and as well as those of the migration tests at high temperature using Tenax as solid simulant. The matrix effect associated with the extraction of the contaminants from the multilayer sample is also discussed.

Typical diffusion behaviour in packaging polymers – application to functional barriers

When plastics are collected for recycling, possibly contaminated articles might be recycled into food packaging, and thus the contaminants might subsequently migrate into the food. Multilayer functional barriers may be used to delay and to reduce such migration. The contribution of the work reported here is to establish reference values (at 40 degrees C) of diffusion coefficients and of activation energies to predict the functional barrier efficiency of a broad range of polymers (polyolefins, polystyrene, polyamide, PVC, PET, PVDC, [ethylene vinyl alcohol copolymer], polyacrylonitrile and [ethylene vinyl acetate copolymer]). Diffusion coefficients (D) and activation energies (Ea) were measured and were compiled together with literature data. This allowed identification of new trends for the log D=f(molecular weight) relationships. The slopes were a function of the barrier efficiency of the polymer and temperature. The apparent activation energy of diffusion displayed two domains of variation with molecular weight (M). For low M (gases), there was little variation of Ea. Focusing on larger molecules, high barrier polymers displayed a larger dependence of Ea with M. The apparent activation energy decreased with T. These results suggest a discontinuity between rubbery and glassy polymers.

Study of barrier properties and chemical resistance of recycled PET coated with amorphous carbon through a plasma enhanced chemical vapour deposition (PECVD) process

Many studies have been carried out in order to make bottle-to-bottle recycling feasible. The problem is that residual contaminants in recycled plastic intended for food packaging could be a risk to public health. One option is to use a layer of virgin material, named functional barrier, which prevents the contaminants migration process. This paper shows the feasibility of using polyethylene terephthalate (PET) recycled for food packaging employing a functional barrier made from hydrogen amorphous carbon film deposited by Plasma Enhanced Chemical Vapour Deposition (PECVD) process. PET samples were deliberately contaminated with a series of surrogates using a FDA protocol. After that, PET samples were coated with approximately 600 and 1200 Angstrons thickness of amorphous carbon film. Then, the migration tests using as food simulants: water, 10% ethanol, 3% acetic acid, and isooctane were applied to the sample in order to check the chemical resistance of the new coated material. After the tests, the liquid extracts were analysed using a solid-phase microextraction device (SPME) coupled to GC-MS.

Post-consumer contamination in high-density polyethylene (HDPE) milk bottles and the design of a bottle-to-bottle recycling process

Six hundred conventional recycled HDPE flake samples, which were recollected and sorted in the UK, were screened for post-consumer contamination levels. Each analysed sample consisted of 40-50 individual flakes so that the amount of analysed individual containers was in the range 24,000-30,000 post-consumer milk bottles. Predominant contaminants in hot-washed flake samples were unsaturated oligomers, which can be also be found in virgin high-density polyethylene (HDPE) pellet samples used for milk bottle production. In addition, the flavour compound limonene, the degradation product of antioxidant additives di-tert-butylphenol and low amounts of saturated oligomers were found in higher concentrations in the post-consumer samples in comparison with virgin HDPE. However, the overall concentrations in post-consumer recycled samples were similar to or lower than concentration ranges in comparison with virgin HDPE. Contamination with other HDPE untypical compounds was rare and was in most cases related to non-milk bottles, which are <2.1% of the input material of the recycling process. The maximum concentration found in one sample of 1 g was estimated as 130 mg kg(-1), which corresponds to a contamination of 5200-6500 mg kg(-1) in the individual bottle. The recycling process investigated was based on an efficient sorting process, a hot-washing of the ground bottles, and a further deep-cleaning of the flakes with high temperatures and vacuum. Based on the fact that the contamination levels of post-consumer flake samples are similar to virgin HDPE and on the high cleaning efficiency of the super-clean recycling process especially for highly volatile compounds, the recycling process investigated is suitable for recycled post-consumer HDPE bottles for direct food-contact applications. However, hand-picking after automatically sorting is recommended to decrease the amount of non-milk bottles. The conclusions for suitability are valid, provided that the migration testing of recyclate contains milk bottles up to 100% and that both shelf-life testing and sensorial testing of the products are successful, which are topics of further investigations.

Identification of chemicals, possibly originating from misuse of refillable PET bottles, responsible for consumer complaints about off-odours in water and soft drinks

Mineral water and soft drinks with a perceptible off-odour were analysed to identify contaminants originating from previous misuse of the refillable polyethylene terephthalate (PET) bottle. Consumers detected the off-odour after opening the bottle and duly returned it with the remaining content to the producers. The contaminants in question had thus been undetected by the in-line detection devices (so-called 'sniffers') that are supposed to reject misused bottles. GC-MS analysis was carried out on the headspace of 31 returned products and their corresponding reference products, and chromatograms were compared to find the possible off-odour compounds. Substances believed to be responsible for the organoleptic change were 2-methoxynaphthalene (10 bottles), dimethyl disulfide (4), anethole (3), petroleum products (4), ethanol with isoamyl alcohol (1) and a series of ethers (1). The mouldy/musty odour (5 bottles) was caused by trichloroanisole in one instance. In some cases, the origins of the off-odours are believed to be previous consumer misuse of food products (liquorice-flavoured alcohol, home-made alcohol containing fusel oil) or non-food products (cleaning products, petroleum products, oral moist snuff and others). The results also apply to 1.5-litre recyclable PET bottles, since the nature and extent of consumer misuse can be expected to be similar for the two bottle types.

Analysis of Residual Volatiles in Recycled Polyethylene Terephthalate

The residual volatiles in recycled polyethylene terephthalate (PET) were analyzed using headspace/GC/MS. Recycled PET samples were made from PET bottles used for beverages, alcohol and soy sauce, and they were recycled in physical recycling plants, chemical recycling plants and superclean-like recycling trials. The physically recycled PET flakes contained small amounts of volatiles such as ethanol, limonene, 2-methyl-1,3-dioxolane, acetone, octanal and nonanal. Most of them originated from foods packed in bottles, and only 2-methyl-1,3-dioxolane was derived from polymer impurities. In contrast, the superclean-like or chemically recycled PET contained no detectable volatiles, like new PET pellets. The PET sheets shaped from physically recycled PET had no detectable volatiles. Not only the chemically and superclean-like recycled PET, but also the physically recycled PET contained no hazardous volatiles. It was concluded that there is no safety concern about volatiles in recycled PET, for the present use.

Analysis of Formaldehyde, Acetaldehyde and Oligomers in Recycled Polyethylene Terephthalate

Formaldehyde (FA), acetaldehyde (AA) and oligomers in recycled polyethylene terephthalate (PET) were analyzed by HPLC. All of the physically recycled PET contained detectable levels of FA, AA and oligomers, and the levels were almost the same as in used bottles. Most superclean-like and chemically recycled PET contained lower levels than new pellets. These compounds showed no decrease upon physical recycling, but showed a marked decrease upon superclean-like recycling. In PET sheets made using physically recycled PET, FA was decreased, though AA was increased by the sheeting process as same as new one. FA, AA and oligomers originated from PET resin and their levels in recycled products were almost equivalent to those in new products. It was concluded that there is no particular safety concern about their presence in recycled PET.

Migration of model contaminants from PET bottles: influence of temperature, food simulant and functional barrier

To simulate post-consumer recycled plastics, selected model contaminants were incorporated into PET bottles using a time saving method. Migration into 3% acetic acid, a cola-type beverage and 95% ethanol was followed during 1 year of storage at 20 and 40 degrees C. Aroma compounds previously found in post-consumer PET material were used as model contaminants. Benzaldehyde was found to migrate to the highest extent. Storage at 40 degrees C affected the bottle material and this might be one reason for the high migration values of these bottles. Migration into ethanol was up to 20 times higher than into 3% acetic acid or a cola-type beverage. Bottles with a functional barrier resisted migration into food simulants even when filled with 95% ethanol and stored for 1 year at 40 degrees C. Differential scanning calorimetry measurements showed that ethanol was interacting with the plastic material. This resulted in a lower glass transition temperature of bottles stored with ethanol compared with bottles stored empty or with other food simulants.