Verification of barrier concept for the final demonstrator

The present Deliverable of the European project CIRCULAR FoodPack combines results previously presented in public deliverables D4.3 “Characterization of input material, benchmarking of cleaning processes” and D4.2 “Evaluation of barrier concepts” in order to evaluate the potential transfer of substances from the 100% Project PE PCR (polyethylene-based layer composed entirely of post-consumer recyclate) integrated in the designed laminate structure, according to current legislative requirements. Taking into account the barrier properties (mainly barrier improvement factors, BIF) of various functional barrier layers (see D4.2), the identification and (semi-)quantification of components of the 100 % Project PE PCR (from Loop3 Cycle1) (see D4.3), and performed calculations on the potential concentrations in food, it was shown that developed laminate structure of CIRCULAR FoodPack has the potential to reduce migration of undesired substances below the threshold levels of toxicological concern. The results and the above conclusion are based on experimental analysis of functional barrier layers produced under defined conditions at a (small) technical scale, however, they are based on only a single production lot. It is recommended to establish the BIF for barrier layers / structures produced at commercial scale and thus statistically validate the BIF values. It should also be noted that the thickness of individual layers (e.g., EVOH) has a significant influence on the overall barrier performance. To ensure long-term effectiveness, the functional barrier(s) must be verified as intact within the laminate structure, thereby meeting the criteria of a functional barrier. For the assessment, the monofilm made of 100 % PE PCR from Loop3 Cycle 1 was characterized with respect to identity and content of migratable components. It is recommended to perform analytical controls of input materials and output recyclates to gain further insights and statistical data on the presence of undesired contaminants. This is in line with the requirements and quality control aspects set out by Regulation No 2022/1616. As an overall conclusion, only the combination of high-quality PE PCR material with functional barrier(s) will be capable to reduce migration of undesired substances below the threshold levels of toxicological concern. Poor qualities of PE PCR (such as the investigated commercial waste fractions, without any further decontamination treatment) will not qualify – even if used behind functional barriers – to be used in sensitive packaging applications. Note: This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 101003806.