As the demand for sustainable packaging continues to grow, brands and manufacturers are looking for ways to reduce their carbon footprint and reliance on virgin plastics. One of the most effective strategies is incorporating post-consumer recycled (PCR) materials into packaging. PCR materials have many sustainability benefits, reducing plastic waste, supporting a circular economy, and helping brands meet evolving eco-friendly packaging regulations.

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Though when it comes to food contact packaging, using PCR material presents unique challenges. Issues such as contamination risks, regulatory approvals, and material performance must be carefully managed to ensure both food safety compliance and sustainability. In this article, we’ll explore the different types of recycled content, the challenges of using PCR in food packaging, and the certifications required for food-safe recycled materials.

Types of Recycled Content in Packaging

Understanding the different types of recycled plastic is essential for choosing the right material for food-grade packaging. There are four key variations of recycled plastic in packaging;

• Post-Industrial Recycled (PIR) Plastic: PIR comes from manufacturing waste—offcuts, production defects, and excess plastic that never reaches consumers. Since it hasn’t been used, it is cleaner and easier to recycle into new packaging solutions.
• Post-Consumer Recycled (PCR) Plastic: PCR is made from plastic waste collected from consumers, such as used bottles, containers, and flexible films. This material undergoes an extensive recycling process to remove contaminants, making it a more complex but essential solution for reducing plastic waste in food packaging.
• Ocean-Bound PCR (OB-PCR) & Ocean Plastic: OB-PCR is sourced from coastal areas where plastic waste is at risk of entering the ocean, while ocean plastic comes from plastics already polluting marine environments. While these solutions help tackle plastic pollution, they are less commonly used in food packaging due to contamination concerns.

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Plastic recycling: Mechanical vs. Chemical

There are two main adopted methods of plastic recycling - mechanical and chemical. Each has their pros and cons, and plays a significant role in the application of PCR in food contact packaging.

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Mechanical Recycling

The most common plastic recycling method, mechanical recycling involves washing, shredding, and reprocessing plastics into new materials. However, this method does not fully remove contaminants like inks, adhesives, and food residues, making it more challenging to use for food-contact applications unless strict food-grade recycling processes are followed.

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Chemical Recycling

A newer technology, chemical recycling breaks plastics down to their molecular level, removing impurities and producing high-quality recycled plastic that can be used in food-safe packaging. Although more expensive and less widely available, this method is expected to play a significant role in the future of sustainable packaging.

Challenges of Using PCR in Food Packaging

While PCR packaging is a viable alternative, it has historically come with several challenges. Contamination is a primary concern, as residual chemicals, inks, and adhesives from previously used plastics must be completely removed to meet food safety standards.

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Beyond contamination, PCR plastics can be harder to process due to their rough texture, making it challenging to achieve high-quality printing. Some recycled resins also tend to be weaker or more brittle than virgin plastic, which can impact packaging durability and machine efficiency. 

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However, despite these challenges, advancements in plastic recycling technologies are improving the usability and safety of food-grade PCR materials.

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Food Contact Certification for PCR Materials

Contrary to popular belief, PCR materials can be certified as food-safe. The most commonly approved material for food-contact use is PCR PET, which is widely used for beverage bottles and food containers. HDPE also has strong food-contact approval, particularly in rigid packaging. PP is gaining recognition, while LDPE and LLDPE are newer entrants in food-safe PCR packaging, with mechanical recycling now enabling food-grade approvals in some cases.

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To obtain food-contact certification, PCR materials must come from controlled recycling streams, undergo strict purification processes, and pass extensive food safety testing.

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Why Brands Should Prioritize Food-Safe PCR Packaging

With global packaging regulations becoming stricter and consumer demand for sustainable products increasing, ensuring that food packaging is both eco-friendly and food-safe is crucial.

• Regulatory Compliance: Governments worldwide are introducing stricter packaging sustainability laws, requiring brands to use certified recycled materials and meet extended producer responsibility (EPR) requirements.
• Consumer Expectations: Shoppers are more aware than ever of sustainable packaging solutions. They expect brands to use food-safe PCR packaging that aligns with eco-friendly practices while ensuring product safety.
• Long-Term Sustainability Goals: Incorporating certified PCR materials into flexible packaging helps brands reduce their environmental footprint, comply with emerging regulations, and future-proof their packaging strategies.

Food Safety Certifications for PCR Packaging

To ensure compliance with food safety standards, brands should look for recycled packaging materials that meet the following certifications:

• FDA Compliance (USA): Governs materials used in direct food contact packaging.
• EFSA (European Food Safety Authority): Sets strict standards for food-safe recycled plastics in the EU.
• ISO 22000 (Food Safety Management): Ensures best practices in food packaging production.
• BRCGS (British Retail Consortium Global Standard): Regulates food-safe packaging suppliers.

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How does food safety testing work? 

At a high level, certifying PCR packaging materials involves rigorous migration testing to ensure that no harmful substances transfer from the packaging to food. Purity screening checks for residual contaminants, while process control audits verify that the recycling and manufacturing processes meet food safety compliance standards.

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Grounded’s Commitment to Food-Safe PCR Packaging

At Grounded, we source our PCR materials from certified recycling streams that meet the highest sustainability and food safety standards. Our materials hold Global Recycled Standard (GRS) and TÜV OK Recycled certifications, ensuring responsible collection and processing.

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To maintain food safety, we implement additional testing and strict quality controls, guaranteeing that our PCR flexible packaging meets international food contact standards. By prioritizing traceability and compliance, we help brands achieve their sustainability goals without compromising on food safety.

The Benefits of Choosing Certified Food-Safe PCR Packaging

For brands looking to transition to sustainable food packaging, using certified food-safe PCR materials provides several advantages. It ensures regulatory compliance, builds consumer trust, and supports sustainable business practices. As more eco-conscious consumers demand plastic-free and recycled packaging, brands must adapt by investing in high-quality PCR solutions that align with both environmental and food safety standards.

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With global sustainability regulations tightening, businesses that integrate food-safe recycled content into their packaging strategies will gain a competitive edge. By choosing certified PCR packaging, brands can drive sustainability leadership while delivering safe, high-quality products to consumers. 

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Read more about the latest in packaging regulations in the UK here and USA here. 

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Ready to explore PCR materials for your packaging? Contact our team today for more information.

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