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Post-consumer recycled content can be PFAS‑free — lab tests on PET with 10–100% PCR showed no detectable PFAS, easing health concerns.
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PFAS fears may be overstated, as contamination didn’t appear despite theoretical worries.
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Ongoing testing and supplier checks are key to maintaining safety as recycling processes evolve.
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Sustainable + safe = possible — brands can confidently use PCR PET with solid protocols in place.
As we strive to protect our planet, people constantly search for ways to make a difference. While not everyone can be a marine scientist working on complex machines cleaning up the oceans, most of us find ourselves taking simpler day-to-day steps like reusing and recycling. Many shoppers deliberately select products with recycled packaging — specifically those containing post-consumer recycled content (PCR) — because it feels like the right thing to do.
…Or is it? (record scratch)
Recently, a concerning question has emerged: Could packages with PCR materials pose health risks due to PFAS contamination?
If you’re in the food packaging industry, you’ve likely heard whispers about this potential issue. The worry? That harmful chemicals known as PFAS (per- and polyfluoroalkyl substances) might be lurking in recycled materials used for food packaging. It’s a troubling thought that could force manufacturers and consumers alike to make an impossible choice between sustainability and safety.
But before we sound the alarm, let’s take a step back and look at what the evidence actually shows.
How Does PCR Get Into Plastic Food Packaging?
Plastics collected for recycling are shredded into small flakes or pellets, which are melted down or chemically processed into new resin. Manufacturers then use this recycled resin to create new plastic products, including food packaging. Using post-consumer recycled content in plastic food packaging helps reduce the demand for virgin materials, conserves resources, and supports the development of a circular economy.
The Concern: PFAS in Recycled Materials
To understand the issue, we need to start with PFAS. These so-called “forever chemicals” have been used in various industries since the 1940s due to their resistance to heat, water, and oil. They can be found in non-stick cookware, water-repellent clothing, and, yes, some food packaging.
The health concerns are significant. Exposure to PFAS has been linked to increased cholesterol levels, changes in liver enzymes, decreased immune response, and even higher risks of certain cancers.
The theoretical worry is straightforward: If plastic that previously contained PFAS is recycled, could those chemicals survive the process and end up in new food containers made with PCR content?
It’s a fair question, and one that deserves a clear answer based on evidence, not speculation.
Putting Theory to the Test
At Inline Plastics, we took this concern seriously enough to investigate it thoroughly. Rather than relying on assumptions or theoretical models, we decided to conduct actual laboratory testing.
To ensure a comprehensive cross-section of the market, we collected various polyethylene terephthalate (PET) containers with different PCR content percentages:
- Products with 10% PCR
- Products with 50% PCR
- Products with 70% PCR
- Products with 100% PCR
All samples were sent to Intertek Laboratory, a certified testing facility, to measure PFAS levels. The testing was straightforward: if PFAS were present in these recycled materials, the tests would detect them.
The Results: What We Actually Found
The results might surprise you: None of the tested containers showed detectable levels of PFAS — regardless of their PCR content percentage.
Even the containers with 100% recycled content came back clean. This evidence suggests that fears of PFAS contamination in PCR food packaging may be overblown.
While we can’t make sweeping statements about all recycled materials in every context, these results are encouraging. They indicate that modern recycling processes might be more effective at preventing PFAS contamination than we initially thought.
What This Means for the Industry
These findings have important implications for everyone involved in the food packaging supply chain:
For manufacturers: You can likely continue using PCR content in your food packaging without introducing PFAS risks, though regular testing remains a prudent measure.
For retailers: When selecting packaging options, you don’t necessarily need to choose between sustainability and safety — you might be able to have both.
And for consumers: You can feel more confident that choosing products in recycled packaging isn’t compromising consumers’ health.
That said, we recommend maintaining some important safeguards:
- Regular testing: While our tests showed no PFAS in current PCR materials, periodic testing ensures this remains true as recycling streams evolve.
- Supplier verification: Ask your packaging or plastic sheet suppliers about their PFAS policies and testing protocols.
- Stay informed: As research on PFAS continues to develop, keep up-to-date with new findings and recommendations.
Moving Forward: Sustainability Without Compromise
The encouraging results of our testing align with what many industry experts have been saying: the presence of PFAS in post-consumer recycled content in food packaging is not the widespread issue some feared it might be.
This doesn’t mean we can become complacent. The industry should continue monitoring for these substances and improving recycling processes. But it does suggest that the goal of increasing recycled content in food packaging remains viable and valuable.
Rather than abandoning our sustainability efforts due to PFAS concerns, we can proceed with greater confidence — knowing that our environmental commitments don’t have to come at the expense of consumer safety.
Finding the Balance
In the beginning of this article, we posed a troubling question: Are we forced to choose between eco-friendly packaging and safety?
Our testing suggests the answer is no. The use of PCR materials in food packaging can be both environmentally responsible and safe for consumers when proper processes and testing are in place.
Sometimes, doing what’s right for the planet and doing what’s right for people aren’t in conflict after all. And that’s good news for everyone.
Do you want to know more about plastic food packaging and our commitment to both safety and sustainability? Check out our Learning Center and explore our collection of articles!