PCR can be safely used in personal care packaging with robust controls – study finds

NORWAY – Post-consumer recycled (PCR) plastic can be used safely in personal care packaging when supported by strict quality controls and smart packaging design, according to new research by Norwegian polymer specialist Norner in collaboration with Orkla Home and Personal Care.

The study found that bottles made from PCR high-density polyethylene (HDPE) show higher chemical migration levels than those made from virgin HDPE.

However, comprehensive migration testing and risk assessment confirmed that these risks can be effectively mitigated through material selection, blending strategies, and multilayer packaging designs.

“Consumer safety has always been a primary concern for brand owners,” said Jorunn Nilsen, principal researcher at Norner.

“This is especially relevant now, as regulations such as the EU’s Packaging and Packaging Waste Regulation (PPWR) are making the use of post-consumer recycled materials mandatory.”

During the project, Norner conducted comparative testing on bottles made from 100% virgin HDPE, 100% PCR HDPE, and hybrid structures, including blends of virgin and recycled material as well as multilayer designs.

The packaging was exposed to 95% ethanol for seven days at 60°C, followed by targeted and non-targeted chemical analyses to identify substances migrating into the simulant.

The results showed that certain substances, including bisphenol A and the fragrance compound hexyl salicylate, were detected in PCR HDPE samples but not in virgin plastic.

This highlighted the importance of rigorous PCR sourcing and quality control, particularly for contact-sensitive personal care applications.

Crucially, the research demonstrated that relatively small design changes can significantly reduce migration risks.

Blending just 10% PCR into virgin HDPE reduced migrating substances by around 60–70% and lowered total migration concentrations by 80–90% compared with bottles made from 100% PCR.

Similarly, multilayer bottles incorporating a thin virgin HDPE inner layer effectively prevented most PCR-derived compounds from reaching the product-contact surface.

The study also found that PCR quality varies widely, with lower-grade materials leading to higher migration levels than well-controlled, high-quality PCR.

Using high-density virgin HDPE as an inner layer was identified as particularly effective in balancing chemical barrier performance with the mechanical requirements of packaging.

Kristine Holmqvist, senior regulatory and safety manager at Orkla Home and Personal Care, said the collaboration has strengthened the company’s confidence in recycled materials.

“Through our partnership with Norner, we have made significant progress and gained confidence in the safe use of recycled materials in our cosmetic packaging,” she noted.

The findings come as personal care brands across Europe prepare for tighter regulatory requirements. Norner said the work anticipates Article 7 of the PPWR, which mandates at least 10% recycled content in contact-sensitive packaging by 2030.

The regulation also requires cosmetic brands to adopt refillable systems by 2027 and demonstrate full recyclability and active recycling at scale by 2035.

As brands navigate this transition, the study suggests that blending strategies, multilayer designs, and stringent PCR quality management will be critical tools for meeting sustainability targets without compromising consumer safety.

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