Safe Recycled Polyolefins for Food Packaging: Integrating Decontamination Methods and Risk Assessment

Abstract Plastic packaging waste remains a major environmental issue due to the large volume generated by its daily use. To address this, new recycling methods are being developed to extend the lifecycle of plastic food packaging without compromising material quality or safety. Recycled polyolefins (rPO), such as high-density polyethylene (HDPE) and low-density polyethylene (LDPE), are of particular interest since they are among the most commonly used food contact materials (FCM). However, their use as FCM remains limited because existing decontamination technologies often fail to ensure the chemical purity required for safe application. This study evaluates the chemical safety of different batches of rPO before and after a lab-scale decontamination process involving high temperature and vacuum. Gas chromatography–mass spectrometry (GC–MS) was used to determine volatile and semi-volatile compounds present in the recycled materials and in the samples obtained from migration tests. Results showed a clear reduction in volatile compounds composition, exceeding 50% in most cases. Migration tests also revealed significantly lower migration levels in decontaminated samples, confirming the efficiency of the process. These findings demonstrate encouraging progress towards the safe use of recycled plastics in food packaging, although further research is needed to address compounds lacking toxicological data and ensure consumer safety and regulatory compliance. Information © The Authors 2026