Is Recycled Plastic Safe for Food Contact? Researchers Say FDA Approval May Not Be Enough

Since 1990, the FDA has approved over 347 applications for recycled plastic in food contact materials, with the number of approvals surging in recent years. In 2024 alone, the FDA approved 27 applications by June. Major players like Coca-Cola, General Mills, and Cadbury are already using recycled plastics in their packaging. However, the FDA’s approval process, which is voluntary and relies heavily on manufacturer-provided data, has been criticized for being lax and not keeping up with scientific advancements regarding chemical hazards in plastics. 

The Risks of Recycled Plastics

Studies suggest that recycled plastics may harbor more toxic chemicals, such as bisphenol-A (BPA), phthalates, and benzene, compared to virgin plastics. These chemicals have been linked to serious health issues, including cancer and hormonal disruptions. Despite this, the FDA’s approval process focuses primarily on preventing pathogen contamination, rather than addressing the risks posed by chemical mixtures. Birgit Geueke, a senior scientific officer at the Food Packaging Forum, points out that recycling can introduce additional hazardous chemicals into the plastic. For instance, one study found 524 volatile organic chemicals in recycled PET compared to 461 in virgin PET, including dangerous substances like styrene, formaldehyde, and antimony. 

FDA’s Outdated Approach

The FDA’s approach has been criticized for not considering the combined effects of multiple chemicals, which can have more severe health impacts than individual chemicals alone. For example, a European study found that a mixture of nine chemicals had a greater impact on children's IQ than expected from individual assessments. Tom Zoeller, professor emeritus at the University of Massachusetts Amherst, argues that the FDA’s current guidelines are outdated and fail to address the complexities of modern toxicology. While the FDA requires that no single chemical in food contact materials exceed 0.5 parts per billion, this threshold does not account for the cumulative effect of the thousands of chemicals used in plastics. 

Industry Self-Regulation

The FDA’s approval process for recycled plastics is largely based on self-regulation by manufacturers. Companies are not required to submit safety data unless the potential contamination level is significant. Even the recommended surrogate testing, which evaluates chemical migration from recycled plastics, is not mandatory. This reliance on industry self-regulation, coupled with the FDA’s focus on cancer risk over other potential hazards, has led to concerns that the agency is prioritizing industry needs over public health. 

Conclusion

The safety of recycled plastics in food contact materials remains a contentious issue. While the FDA maintains that its guidelines are rigorous, experts argue that the agency’s approval process is insufficient to protect consumers from the complex chemical risks associated with recycled plastics. As the use of recycled content in packaging continues to rise, there is a growing need for more stringent regulations to ensure that these materials are truly safe for food contact.