European circular economy goals require the use of recycled polymers in sensitive applications such as food packaging. As plastic recyclates can contain unknown post-consumer substances, the European Food Safety Authority evaluates recycling processes using a worst-case assumption: all contaminants are DNA-reactive mutagens/carcinogens with extremely low safety thresholds. The current data are insufficient to estimate whether this assumption is justified. To provide scientific evidence on the presence of DNA-reactive mutagens in recycled plastics, 119 input and output samples from plastic recycling were tested with a miniaturized Ames test. DNA-reactive mutagens were not detected in recycled polyethylene terephthalate, which is already approved for food contact. However, other types of recycled plastics (polyethylene, polypropylene and polystyrene), which are currently unauthorized for food contact, showed DNA-reactive, mutagenic effects in a total of 51 samples. The DNA-reactive substances that are responsible for the detected mutagenic activity could not be identified by comparison of the bioassay data with analytical results from a chromatographical screening. The data from the Ames test analysis of different independent batches and a comparison of input and output material indicate that the DNA-reactive contaminants are not randomly introduced through the misuse of recycled packaging by consumers, but are systematically formed during the recycling process from precursors in the input. This publication highlights the need to identify the source for this critical contaminant to enable the future use of polyethylene, polypropylene and polystyrene in sensitive applications.

The Ames assay is the standard assay for identifying DNA-reactive genotoxic substances. Multiple formats are available and the correct choice of an assay protocol is essential for achieving optimal performance, including fit for purpose detection limits and required screening capacity. In the present study, a comparison of those parameters between two commonly used formats, the standard pre-incubation Ames test and the liquid-based Ames MPF™, was performed. For that purpose, twenty-one substances with various modes of action were chosen and tested for their lowest effect concentrations (LEC) with both tests. In addition, two sources of rat liver homogenate S9 fraction, Aroclor 1254-induced and phenobarbital/β-naphthoflavone induced, were compared in the Ames MPF™. Overall, the standard pre-incubation Ames and the Ames MPF™ assay showed high concordance (>90%) for mutagenic vs. non-mutagenic compound classification. The LEC values of the Ames MPF™ format were lower for 17 of the 21 of the selected test substances. The S9 source had no impact on the test results. This leads to the conclusion that the liquid-based Ames MPF™ assay format provides screening advantages when low concentrations are relevant, such as in the testing of complex mixtures.

In order to recycle plastic waste back to food contact materials (FCMs), it is necessary to identify hazardous substances in plastic packaging that pose a toxicological risk. Printing inks on plastics are not yet designed to withstand the high heat stress of mechanical recycling processes and therefore require hazard identification. In this study, virgin polypropylene (PP) foils were printed with different types of inks (UV-cured, water-based) and colour shades. Thermal analysis of printed foils and pigments was performed using differential scanning calorimetry (DSC). Samples were then thermally treated below and above measured thermal events at 120 °C, 160 °C, 200 °C or 240 °C for 30 min. Subsequently, migration tests and miniaturised Ames tests were performed. Four out of thirteen printed foils and all three pigments showed positive results for mutagenicity in miniaturised Ames tests after thermal treatment at 240 °C. Additionally, pre-incubation Plate Ames tests (according to OECD 471) were performed on three pigments and one printed foil, yielding two positive results after thermal treatment at 240 °C. These results indicate that certain ink components form hazardous decomposition products when heated up to a temperature of 240 °C. However, further research is needed to gain a better understanding of the chemical processes that occur during high thermal treatment.

To fulfil the European Green Deal targets and implement a circular economy, there is an urgent need to increase recycling rates of packaging materials. However, before recycled materials can be used in food contact applications, they must meet high safety standards. According to the European Food Safety Authority (EFSA), a worst-case scenario must be applied and unknown substances must be evaluated as being potentially genotoxic. The Ames test, which detects direct DNA-reactive effects, together with chromatographic analysis is very promising to complement risk assessment. This study aims to evaluate the effectiveness of functional barriers in ten different samples, including virgin and recycled LDPE foils. FT-IR analysis did not show major differences between virgin and recycled films. Light microscopy revealed differences in quality and an increased number of particles. GC-MS analysis detected and quantified 35 substances, including eight unknowns. Using a miniaturized version of the Ames test, four of ten samples tested positive in two individual migrates up to a dilution of 12.5%. All virgin LDPE materials tested negative; however, recycled material F showed an increased mutagenic activity, with an n-fold induction up to 28. Samples with functional barriers lowered migration and reduced mutagenicity. Nonetheless, further investigations are needed to identify possible sources of contamination.