The UN food safety agency warns that recycled plastics and alternative packaging materials can help reduce waste, but only if recycling systems are carefully managed to prevent harmful chemicals from migrating into food.
“Plastic waste is a growing global problem. Better and more effective recycling is essential and is part of the solution,”said Vittorio Fattori, FAO food safety officer.
“While we must do better at reducing plastic pollution and improving recycling, We must ensure that by trying to solve a problem in one area, we do not create new ones.”
Food packaging plays a central role in modern food systems by preserving quality, extending shelf life and reducing food loss. The sector is growing rapidly and the market is projected to grow from an estimated $505 billion in 2024 to more than $815 billion by 2030.
However, the growth of plastic packaging has fueled environmental concerns. Less than 10 percent of global plastic waste has been recycled so faralthough that proportion is expected to increase as countries pursue sustainability goals.
Plastic Recycling Steps for Food Contact Materials: Food Safety Considerations.
A complex recycling stream
Unlike many other recycled products, food packaging must meet strict chemical safety standards.
Plastic food containers and wrappers can contain thousands of substances used during manufacturing, including stabilizers, coatings, pigments and plasticizers. Additional contaminants may enter during the recycling process due to improper sorting, environmental exposure, or prior consumer use.
The FAO analysis also found that recycled plastics may contain higher levels of substances such as metals, flame retardants, phthalates and persistent organic pollutants than newly produced plastics.
Experts highlight that recycled plastics approved for food use can be as safe as virgin plastics when they undergo rigorous cleaning, decontamination and regulatory review. In the European Union (EU), for example, authorized recycled materials in contact with food must meet the same standards as new plastics.
“The main finding of the report is: While recycled plastic and alternative food contact materials can offer environmental benefits, they can also raise some important food safety questions.”said Mr. Fattori.
“Applying [the principles of a] The circular economy is important, it is fundamental. But it has to be done well.”
New materials, new questions.
The analysis also examines alternative packaging materials, including bioplastics, plant fibers and protein-based materials, which are increasingly promoted as more sustainable substitutes for conventional plastics.
But “biobased” does not always mean biodegradable. Some materials derived from renewable sources, such as corn or sugar cane, are chemically similar to fossil fuel-based plastics, while others decompose only under specific conditions.
The report warns that plant-based packaging can introduce agriculture-related risks, including pesticide residues, toxins and heavy metals. Protein-based materials can also allow allergens, such as gluten, to migrate into foods.
Like conventional plastics, many alternatives also rely on chemical additives to improve performance and some still lack sufficient data on long-term safety.
Plastic is collected for recycling in the South African city of Johannesburg.
Microplastics are not well understood
The analysis also addresses growing public concern about microplastics and nanoplastics found in food and beverages. Scientists have detected small plastic particles in human blood, lungs, breast milk and placentas, confirming widespread exposure.
But regulators lack reliable, harmonized methods to consistently detect and measure those particles, making it difficult to assess clear risks to human health.
The report notes that recycling facilities themselves can contribute to microplastic pollution, particularly during mechanical recycling processes that break plastics into smaller fragments.
“It all has to start with well-controlled recycling processes, including cleaning and removing chemical contaminants,”said Mr. Fattori.
Many plastic products, such as beverage bottles, are made for single use.
Towards global standards
The findings are expected to inform ongoing discussions at the Codex Alimentarius Commission, the international food standards body established by FAO and the World Health Organization (WHO).
Countries currently apply different regulatory approaches to recycled plastics and food contact materials, creating challenges for trade and consumer protection, the report notes.
“Our role is to provide support to countries in terms of, first, harmonizing, for example, regulations on food safety implications related to packaging materials,”said Mr. Fattori.
According to the report, harmonized global standards would help countries strengthen science-based food safety systems and at the same time help countries reduce plastic waste.
