Safety Assessment of Recycled Plastics from Post-Consumer Waste with a Combination of a Miniaturized Ames Test and Chromatographic Analysis

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.