The UN’s 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 efficient recycling is fundamental and is part of the solution,” said Vittorio Fattori, a food safety officer at the FAO.
“While we need to be better at reducing plastic pollution and improving recycling, we need to make sure we don’t create new ones by trying to solve a problem in one area.”
Food packaging plays a central role in modern food systems by maintaining quality, extending shelf life and reducing food loss. The sector is growing rapidly and the market is expected to grow from an estimated $505 billion in 2024 to more than $815 billion in 2030.
Still, the growth in plastic packaging has fueled environmental concerns. Less than 10 percent of global plastic waste has so far been recycledalthough that share is expected to increase as the countries pursue sustainability goals.
Steps to plastic recycling 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 through improper sorting, environmental exposure, or past 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 emphasize that recycled plastic approved for food use can be as safe as virgin plastic when it undergoes rigorous cleaning, decontamination and regulatory review. In the European Union (EU), approved recycled materials that come into contact with food must meet the same standards as new plastics.
“The main conclusion of the report is: while recycled plastics and alternative materials in contact with food can provide environmental benefits, they can also raise some important questions about food safety,” Mr. Fattori said.
“Applicant [the principles of a] circular economy is important, it is fundamental. But it has to be done right.”
New materials, new questions
The analysis also examines alternative packaging materials, including bioplastics, plant fibers and protein-based materials, which are increasingly being promoted as more sustainable substitutes for conventional plastics.
But “bio-based” does not always mean biodegradable. Some materials derived from renewable sources, such as corn or sugarcane, are chemically similar to fossil fuel-based plastics, while others only degrade under special conditions.
The report warns that plant-based packaging can pose risks linked to agriculture, 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 long-term safety data.
Plastic is collected for recycling in the South African city of Johannesburg.
Microplastics are poorly understood
The analysis also addresses growing public concern about microplastics and nanoplastics found in food and beverages. Scientists have detected tiny plastic particles in human blood, lungs, breast milk and placentas, confirming widespread exposure.
But regulators lack reliable and harmonized methods to consistently detect and measure these 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 must all start with well-controlled recycling processes, including cleaning and removal of chemical pollutants,” said Mr. Fattori.
Many plastic products, such as drinking bottles, are made for single use only.
Towards global standards
The findings are expected to inform ongoing discussions in the Codex Alimentarius Commission, the international food standards body established by the FAO and the World Health Organization (WHO).
Countries currently apply different regulatory approaches to recycled plastics and food contact materials, creating trade and consumer protection challenges, the report notes.
“Our role is to provide support to countries in terms of, firstly, harmonizing, for example, regulations on food safety implications related to packaging materials,” said Mr. Fattori.
According to the report, harmonized global standards will help countries strengthen science-based food safety systems while helping countries reduce plastic waste.
