Functional barrier concept in food packaging within the circular economy
Résumé
In line with the European Single-Use Plastic Directive 2019/904 and the France's Anti-Waste and Circular Economy Law (n°2020-105), the use of recycled materials in food packaging has grown significantly. This is regulated by the (EU) 2022/1616, which requires recycled materials to meet the same safety standards as virgin materials through strict sourcing and decontamination protocols. A key innovation supporting this objective is the functional barrier – a barrier layer introduced between food and the recycled layer – recognized under the Regulation (EU) 10/2011. This presentation highlights results from collaborative projects at Joint Technological Unit 22.07 (SafeMat). The chemical risks of non-decontaminated recycled polyethylene terephthalate (rPET) in ABA trays were analyzed. These trays were composed of a recycled middle layer enclosed by virgin or approved recycled material layers acting as functional barriers. This case study was used for the development of a mathematical optimization tool for functional barriers for polyolefins using a concept of equivalent safety to provide iso-safety abacus for decontamination and dimensioning of functional barriers using mass transfer modeling under worst-case scenarios. The results show several outcomes: functional barriers have a service life highly dependent on sourcing, process, and storage conditions; food shelf-life should integrate a safety margin specific to chemical risks; not all recycled streams are suitable for a every food application. Practical recommendations to enhance the integration of recycled materials into food packaging include improved sorting and decontamination practices, robust monitoring systems, and optimized barrier layer designs to ensure long-term sustainability and compliance with food safety regulations.