The Food and Agriculture Organization of the United Nations is calling for stronger risk assessment of recycled plastic food packaging, warning that the transition to more sustainable food contact materials must not compromise consumer safety. In its new report, Food safety implications of recycled plastics and alternative food contact materials, FAO highlights the need for globally harmonised standards as demand for environmentally friendly packaging continues to rise.

The report comes at a decisive moment for the food packaging sector. The global market was estimated at USD 505.27 billion in 2024 and is projected to reach USD 815.51 billion by 2030. Growth is being driven by snacks, ready-made meals, fast food, confectionery and bottled beverages, all of which depend on packaging to protect quality, extend shelf life and support modern consumption patterns.

FAO’s central message is clear: recycled packaging can support sustainability, but food safety must remain at the centre of circular packaging strategies.

Food contact materials play an important role in reducing food loss and waste. By protecting products from contamination, moisture, oxygen and physical damage, packaging helps preserve food quality and improve the efficiency of agrifood systems. However, FAO warns that the increasing use of recycled plastics introduces chemical safety questions that must be addressed through science-based evaluation.

The concern is not recycling itself, but the quality and control of the recycling process. Recycled plastic streams can contain residues from previous uses, non-food packaging, additives, inks, adhesives or other substances that may migrate into food if not properly removed. For food-grade recycled materials, sorting, cleaning and decontamination must therefore be designed specifically for food contact applications.

FAO also draws attention to alternative food contact materials, including bio-based packaging made from natural and renewable resources such as corn, sugarcane and cassava. These materials can reduce dependence on fossil-based plastics, but they may introduce other hazards, including pesticides, natural toxins or allergens. This means that every alternative material must be assessed for safety, not only promoted for its environmental benefits.

Another emerging issue is the use of new intentionally added substances, including nanomaterials, which can improve packaging performance or enable active packaging functions. These innovations may help extend shelf life or enhance protection, but they also require careful toxicological review and regulatory clarity before they are widely adopted in food packaging.

• Food-grade recycling requires controlled input streams and validated decontamination.
• Bio-based materials must be assessed for possible natural toxins, allergens or pesticide residues.
• Nanomaterials need robust evaluation before broad food contact use.
• Microplastics and nanoplastics require validated detection methods.
• Global harmonisation can support safety, innovation and international trade.

The report also highlights the difficulty regulators face when assessing exposure to microplastics and nanoplastics in food and beverages. FAO notes that validated analytical methods for detection and identification are still lacking, making it difficult for authorities to determine clear human health risks. Developing reliable testing methods will be essential for future regulation and consumer confidence.

Regulatory fragmentation is another major challenge. Different national rules for recycled plastics and alternative food contact materials could create trade barriers and uncertainty for packaging producers, food manufacturers and retailers. FAO argues that harmonised global frameworks would support robust risk assessments while helping countries reduce plastic waste safely.

The findings are expected to inform discussions within the Codex Alimentarius Commission, the intergovernmental body established by FAO and the World Health Organization to develop international food standards. Codex discussions on recycled plastics in food packaging have already shown the need for greater alignment between countries.

For packaging companies, FAO’s report reinforces an important principle: circularity must be built on verified safety. Recycled content, bio-based materials and advanced coatings can all contribute to more sustainable packaging, but only if supported by traceability, testing, clean input streams and transparent regulatory standards.

For food brands, the message is equally relevant. Sustainability claims must be matched by food safety assurance. A package that reduces plastic waste but introduces contamination risk will not be acceptable to consumers, regulators or trading partners. The next phase of sustainable food packaging will therefore depend on close cooperation between recyclers, converters, scientists, food companies and policymakers.

FAO’s warning should be seen as a call to strengthen, not slow, circular packaging innovation. With robust science, harmonised standards and controlled recycling systems, recycled food contact materials can help reduce plastic waste while protecting public health. The challenge for the industry is to ensure that environmental progress and food safety advance together.