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.

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.