Linking Degradation Pathways, Additive Transformation, and Contaminant Profiles in Post-Consumer HDPE: Implications for Recycling Quality

The chemical complexity of post-consumer plastics represents a major challenge for achieving high-quality recycling. In this study, post-consumer high-density polyethylene (HDPE) packaging materials were analysed using pyrolysis–gas chromatography–mass spectrometry (Py-GC/MS) to investigate relationships between compound origin, degradation pathways, and contaminant profiles. More than one hundred organic compounds were detected and classified into four main groups: product-related inputs, polymer formulation chemistry, polymer degradation processes, and external contamination. Polymer degradation products, particularly radical rearrangement and cyclisation compounds, represented the most diverse group, indicating advanced transformation of the polymer matrix associated with repeated processing. Additive-derived compounds, including phenolic structures and epoxide-containing species, contributed to the pool of non-intentionally added substances (NIAS), while persistent compounds, such as fluoropolymer-derived residues, were detected across most samples. In contrast, product-related inputs showed high variability and a generally lower contribution. Multivariate analysis revealed that samples were not clustered according to product category but rather distributed along gradients defined by degradation, additive transformation, and contamination processes. These findings demonstrate that the chemical composition of recycled HDPE is determined or influenced by multiple independent factors. The results support the need for chemistry-informed recycling strategies.