Food packaging may release 1,000 tonnes of microplastics into food annually, report suggests

Plastic food packaging could release around 1,000 tonnes of microplastic particles into food and drinks every year, according to new global research highlighting a previously underestimated exposure pathway.

The report, From Pack to Plate, published by Earth Action in collaboration with rePurpose Global, is described as the first global synthesis examining how micro- and nanoplastics may migrate from food packaging into food and beverages.

Researchers estimate the particles released annually are equivalent to the weight of more than 600 cars. They claim individual consumers may ingest an average of around 130 milligrams of plastic particles each year, rising to more than one gram annually for high-use consumers - representing potentially hundreds of millions of particles.

For years the debate around microplastics focused on pollution in the environment.

Now we know of the direct pathway to human exposure through the food we eat every day.

This report identifies the scale of the problem but also points to the solutions.

If policymakers and industry start treating particle release as a real safety consideration, alongside chemical migration, we have clear opportunities to reduce exposure.”

 

Julien Boucher, PhD, Head of Research and Co-CEO of Earth Action

Most particles identified were smaller than 150 micrometres, which some studies suggest may be small enough to penetrate cell barriers and interact with biological systems. The report also notes that plastics can contain complex chemical mixtures, including endocrine-disrupting and carcinogenic substances, meaning micro- and nanoplastics may also carry chemical exposure.

Packaging design and usage conditions drive exposure

A key finding of the study is that microplastic migration from packaging is largely predictable and driven by three factors: material choice, packaging design and real-world use conditions.

Researchers say design features such as caps, closures and multi-component packaging structures can introduce friction points that increase particle release during repeated opening and handling.

The report suggests use conditions may further amplify the effect. Sunlight and UV exposure may increase particle release by up to two orders of magnitude, while heat stress from processes such as hot filling or microwaving can weaken materials and increase particle detachment.

Although packaging is not the largest environmental source of microplastics, its direct and continuous contact with food and drinks creates a concentrated ingestion pathway for humans.

The study estimates polyethylene terephthalate (PET) bottles account for roughly one-third of packaging-related exposure, followed by rigid PET food packaging and flexible polyethylene (PE) packaging.

Industry solutions and regulatory gaps

Researchers say this concentration means targeted design improvements could help reduce microplastic migration. Practical measures outlined in the report include limiting UV exposure during transport and retail display, redesigning high-stress components such as caps and closures, and testing packaging under realistic use conditions including heating and repeated handling.

The data makes one thing clear: better choices upstream can prevent billions of particles reaching food before it ever gets to consumers.

A relatively small number of packaging formats and supply-chain conditions drive most exposure.

That means the industry has a real opportunity and responsibility to redesign packaging systems to reduce these emissions.”

 

Svanika Balasubramanian, Chief Circularity Officer & Founder of rePurpose Global

The report also highlights what researchers describe as a regulatory gap in food safety frameworks. Consuming micro- and nanoplastics often involves simultaneous exposure to chemical substances within plastic materials.

According to the research, ingesting 100–200 milligrams of micro- and nanoplastics could correspond to roughly 50 milligrams of chemical exposure. Yet the researchers suggest current food-contact regulations largely account for neither particle release nor this combined exposure profile, despite all three originating from the same materials.

For a long time, food packaging has been viewed as essentially inert within regulatory safety frameworks.

But decades of research show that plastics can release both chemicals and particles into food during normal use.

Micro- and nanoplastics add another dimension to this issue and underline the need to better assess the stability and safety of materials used in food packaging.”

 

Dr. Jane Muncke, Managing Director and Chief Scientific Officer at the Food Packaging Forum