Prospects for application of post-consumer used plastics in food packaging

The COVID-19 pandemic redefining the mundane food packaging material industry?

COVID-19 pandemic has been the talk of the globe, as it swept across the world population, changing enumerable aspects. The pandemic affected all sectors directly or indirectly. The food sector took a direct hit. The food packaging sector rose to the occasion to serve and feed the pandemic affected, but there were interactions, reactions, and consequences that evolved through the course of the journey through the pandemic. The aim of this perspective is to address the importance of the food packaging industry (from the COVID-19 point of view) and to highlight the unpreparedness of the food packaging materials, for times as these. As the world has been asked to learn to live with Corona, improvisations are definitely necessary, the lapses in the system need to be rectified, and the entire packaging industry has to go through fortification to co-exist with Corona or confront something worse than Corona. This discussion is set out to understand the gravity of the actual situation, assimilating information available from the scattered shreds of reports. Food packaging materials were used, and plastic wastes were generated in bulks, single-use plastics for fear of contamination gained prominence, leading to an enormous turnover of wastes. Fear of Corona, sprayed overloads of sanitizers and disinfectants on food package material surfaces for surface sterilization. The food packages were tailored for food containment needs, never were they planned for sanitizer sprays. The consequences of these sanitization procedures are unprecedented, neglected and in the post-COVID-19 phase no action appears to have been taken. Corona took us by surprise this time, but next time atleast the food packaging industry needs to be fully equipped. Speculated consequences have been reviewed and plausible suggestions have been proposed. The need for extensive research focus in this direction in exploring the ground-reality has been highlighted.

Food packaging's materials: A food safety perspective

Food packaging serves purposes of food product safety and easy handling and transport by preventing chemical contamination and enhancing shelf life, which provides convenience for consumers. Various types of materials, including plastics, glass, metals, and papers and their composites, have been used for food packaging. However, owing to consumers' increased health awareness, the significance of transferring harmful materials from packaging materials into foods is of greater concern. This review highlights the interactions of food with packaging materials and elaborates the mechanism, types, and contributing factors of migration of chemical substances from the packaging to foods. Also, various types of chemical migrants from different packaging materials with their possible impacts on food safety and human health are discussed. We conclude with a future outlook based on legislative considerations and ongoing technical contributions to optimization of food-package interactions.

Predicting diffusion coefficients of chemicals in and through packaging materials

Most of the physicochemical properties in polymers such as activity and partition coefficients, diffusion coefficients, and their activation with temperature are accessible to direct calculations from first principles. Such predictions are particularly relevant for food packaging as they can be used (1) to demonstrate the compliance or safety of numerous polymer materials and of their constitutive substances (e.g. additives, residues…), when they are used: as containers, coatings, sealants, gaskets, printing inks, etc. (2) or to predict the indirect contamination of food by pollutants (e.g. from recycled polymers, storage ambiance…) (3) or to assess the plasticization of materials in contact by food constituents (e.g. fat matter, aroma…). This review article summarizes the classical and last mechanistic descriptions of diffusion in polymers and discusses the reliability of semi-empirical approaches used for compliance testing both in EU and US. It is concluded that simulation of diffusion in or through polymers is not limited to worst-case assumptions but could also be applied to real cases for risk assessment, designing packaging with low leaching risk or to synthesize plastic additives with low diffusion rates.

Partition coefficients in food/packaging systems: a review

Food contamination can result from various interactions between food and packaging materials. Migration of volatiles, additives, monomers and oligomers from packaging materials into food or adsorption of volatile compounds from the food by the polymer are important considerations from safety, hygienic and economic points of view. The term 'migration' includes two phenomena (partition and diffusion) that can be important in determining the concentration of contaminants in a food system at any time. An estimation of the partition coefficient, K, in food/packaging systems has been the major objective of numerous different studies. Various parameters can influence K such as temperature, pH, the chemical structure of the migrant, molecular size and structure, fat content, and degrees of crystallinity. Some theoretical approaches such as the quantitative structure-property relationship method could be of interest in the near future.

Migration of Substances from Food Packaging Materials to Foods

The employment of novel food packaging materials has increased the number of occurring hazards due to the migration from packaging material to the packaged food. Although polymers have mainly monopolized the interest of migration testing and experimentation, recent studies have revealed that migration also occurs from "traditional" materials generally considered to be safe, such as paper, carton, wood, ceramic, and metal. The regulations and the directives of the EU tend to become stricter in this respect. The emphasis is on reaching a consensus in terms of food simulants and testing conditions for migration studies. Furthermore, the list of hazardous monomers, oligomers, and additives continues to augment in order to ensure that the consumer safety is in current agreement with the HACCP, which is continuously gaining ground.

Contaminants and levels of occurrence in washed and shredded poly(ethylene terephthalate) from curbside collection. II: Validation of extraction procedures, particle size sampling and crystallinity

Part I of this study showed that washed and dried, shredded poly(ethylene terephthalate) (PET) (flake) obtained from curbside collection when Soxhlet extracted contained 26 semivolatile contaminants below the US FDA threshold of 215 ppb and six above this level. This paper reports the validation of the Soxhlet extraction technique by comparison with total dissolution with trifluoroacetic acid (TFA). The work was carried out for two of the three particle size ranges obtained by grinding the PET flake (300-425 and 425-700 microm) and for the unground flake. Further validation was undertaken by comparison of contaminant levels determined by total dissolution with TFA and sonication with dichloromethane (DCM) using flake ground to the 0-300 microm size range. The levels of contaminants increased with decreasing particle size range, but X-ray diffraction measurements of degrees of crystallinity were similar for each PET particle size range, thus showing that the differences in contaminant levels were not due to variable percentages of the amorphous material from the tops and bottoms of shredded bottles, relative to the amounts of crystalline PET from the mid-sections of the bottles. Hence, it was postulated that the variations in contaminant levels were due to selective grinding of the more highly contaminated surfaces, whilst the larger particles incorporated the less contaminated interior material. The grinding was also strongly selective with respect to the amorphous flake. Analysis of the segregated amorphous and crystalline flake phases indicated that many contaminants were similarly absorbed into both phases, whilst some were preferred by the amorphous PET and others were preferred by the crystalline PET.

Physicochemical and mechanical properties of experimental coextruded food-packaging films containing a buried layer of recycled low-density polyethylene

Migrational, permeation, and tensile properties of experimental five- and eight-layer coextruded and laminated films containing a middle buried layer of recycled low-density polyethylene (LDPE) comprising 40-50% bw of the multilayer structure were determined. Respective films containing 100% virgin LDPE as the buried layer were taken as controls. Results showed that the percentage of recycled LDPE in the multilayer structure did not affect overall migration values to distilled water, 3% acetic acid, and iso-octane. In all cases, overall migration values were lower than the upper acceptable limit (10 mg/dm(2)) set by the European Union. Transmission rate values to O(2), CO(2), and water vapor were also not affected by the percentage of recycled LDPE in the multilayer structure. On the basis of O(2) transmission rates, low-barrier, barrier, and high-barrier multilayer structures were produced. Likewise, tensile properties (tensile strength, percent elongation at break, and Young's modulus) were not affected by the percentage of recycled material in the multilayer structure. Finally, all experimental films produced no adverse effects in taste or odor of the food-contacting phase tested. The above findings are discussed in relation to the high quality of the primary LDPE scrap used throughout this work in combination with the functional barrier hypothesis. On the basis of the present results it is proposed that primary LDPE scrap may be used as a middle layer comprising 40-50% bw of multilayer food-packaging films without any compromise in migrational, barrier, mechanical, and organoleptic properties.

Simple models for assessing migration from food-packaging films

Owing to their simplicity, two migration models based on Fick's Second Law have been frequently used for the assessment of migration of additives and contaminants from food-packaging films. While the two models are known to provide accurate estimates of diffusion coefficients for complete migration, they could generate considerable estimation errors for significantly partitioned migration. In this paper, the applicability of the two models to partitioned migration is defined by examining the assumptions and derivations of the two models as well as their errors in estimating diffusion coefficients. Furthermore, a simple migration model, based on more realistic assumptions than the two models, is proposed. The proposed model can provide far better estimates of diffusion coefficients for partitioned migration than the two models.

Desorption behavior of sorbed flavor compounds from packaging films with ethanol solution

Desorption behavior of sorbed flavor compounds such as ethyl esters, n-aldehydes, and n-alcohols from LDPE and PET films was investigated in 0 to 100% (v/v) ethanol solutions at 20 degrees C, 50 degrees C, and 60 degrees C. In both films, the desorption apparently increased with increasing ethanol concentration and treatment temperature, depending on the compatibility of the flavor compound with the solvent. Namely, the partition coefficient of ethyl esters, n-aldehydes, and n-alcohols in the LDPE film turned out to be approximately zero at >/=60%, >/=80%, and >/=40% (v/v) ethanol, respectively (for PET film, >/=80%, >/=80%, and >/=40% (v/v) ethanol concentrations were required for complete desorption, respectively). As for physical properties (heat of fusion, melting point, and tensile strength and elongation at break) of LDPE and PET films, there were no significant differences between intact film and the treated film with 60% (v/v) ethanol for 30 min at 60 degrees C. These results suggest that it is possible to apply a desorption solvent such as ethanol solution for desorption of sorbed flavor compounds from packaging films with no physical change in the film properties by this desorption treatment.

Study of diffusion through LDPE film of Di-n-butyl phthalate

The apparent diffusion coefficients (D) across a PE-LD film of Di-n-butyl phthalate (DnBP) dissolved in isooctane and ethanol, were calculated in different ways and compared. DnBP, a common plasticizer of plastics and printing inks, may be a possible contaminant of flexible packaging and PE-LD is the most common food-contacting polymer. To perform diffusion measurements, small plastic sachets filled with solutions of the contaminant were used at three different temperatures. The D coefficients of the two solvents and dissolved DnBP were calculated using the lag time method, a formula taking into account the molar weight and absolute temperature, and an equation based on the initial concentration and the amounts migrated after subsequent times. The results demonstrated great solvent interference in the plasticizer diffusion across polyethylene; in particular as far as isooctane is concerned, a remarkable co-diffusion of both the plasticizer and the non-polar solvent must be assumed. Isooctane quickly penetrates PE-LD but ethanol also diffuses across PE-LD, although at a greatly reduced speed. These facts must be considered for realistic prediction of migration or effectiveness of the functional barrier.