Food-Grade Plastics

"Understanding role of Food Grade Plastic Materials in Food Industries and Impact on Health: The science behind the grade, migration testing and safety standards."

Questions to be Answered...!!!

1. Do you really understand the concept of Food-Grade Plastics and Non-Food Grade Plastics?
2. Why it's important to understand the role of Food Grade Plastics and Plastic migration into food and does it really link with serious health issues such as Cancer?
3. How safe is it to repeatedly use of Food-Grade Plastics with food contact surfaces?
4. How do food businesses operator get certificate that food contact plastic material is food-grade in India?

WHAT'S THE RISK?
FOOD PACKAGING

Food Safety First!

1. Why it's important to understand role of Food Grade Plastic and Plastic migration into food & does it really link with serious health issue such as Cancers?

• Research studies has been shown that plastic migration can occur when non-food grade plastics are used in contact with edibles. This migration involves chemicals from the plastic leaching into the food, potentially leading to health risks. Research has shown that certain chemicals in plastics, like bisphenol A (BPA) and phthalates, are endocrine disruptors and may increase cancer risk. For instance, BPA is linked to breast and prostate cancers due to its estrogen-mimicking properties. Phthalates, often used to soften plastics, are also associated with various cancers. The International Agency for Research on Cancer (IARC) has classified some of these chemicals as potential carcinogens. Proper regulation and the use of food-grade plastics can help mitigate these risks. Testing and certification ensure that materials in contact with food meet safety standards, reducing the potential for harmful chemical migration.

2. How is food contact plastic material considered Food Grade Plastic in India?

• In India, plastics are widely used for packaging food. While the high-molecular-mass polymers in plastics are generally safe because they are inert and don't dissolve in food, there is a concern about the transfer of certain substances from the plastic to the packaged items. These substances can include additives, impurities like leftover monomers, catalysts, solvents used in production, and small polymer fragments. Although the risk of acute toxicity from these trace amounts is low, the gradual buildup of these substances over time could potentially pose serious health risks to consumers.
• In India, plastic materials used for food contact shall be made from food-grade materials, which means they should be non-toxic, non-reactive, and safe for use with food. The FSSAI, under the Food Safety and Standards (Packaging) Regulations, 2018, adopted standards on the food contact plastic materials for food packaging which are established by BIS government body.
• BIS has established standards for different plastic material such as IS 10146:1982 (Polyethylene for its safe use in contact with foodstuffs, pharmaceuticals, and drinking water) and IS 10910:1984 (Specification for polypropylene) are examples of standards that specify the types of plastic materials that can be used for food contact applications.
• Plastic Manufacturers shall ensure that the manufactured plastic complies with the specific standards when he or she wants to claim food grade which is prescribed by BIS and that adopted by FSSAI for food manufacturer.

3. What's the basic fundamentals of Plastic Migration relation with Food Grade Plastic or Non-Food Grade Plastic:

Non-food-grade plastics:

• This focuses on the interaction between the plastic and the food, ensuring that any migration of substances from the plastic into the food remains within safe limits. The migration standards to claim food grade which is prescribed by BIS which is adopted by FSSAI for food manufacturer. FSSAI regulates this through the Food Safety and Standards (Packaging) Regulations, which set migration limits for different substances.
• The BIS also outlines methods for testing migration in standards like IS 9845:1998 (Determination of overall migration of constituents of plastics materials and articles intended to come into contact with foodstuffs).
• Migration testing is a critical part of ensuring that plastic materials used for food contact are safe. These tests are conducted to simulate different conditions (e.g., temperature, contact time, type of food) that the plastic may encounter during its use.
• FSSAI requires that food contact materials do not exceed the prescribed migration limits. For instance, certain substances like heavy metals, plasticizers, and other additives have defined limits to ensure they do not migrate into food at levels that could pose health risks.

Non-food-grade plastics:

• Formulations and Additives: The key difference between food-grade and non-food-grade plastics often lies in the specific formulations and additives used. Even a type of plastic generally regarded as food-grade can be non-food-grade if it contains non-approved additives or fails to meet regulatory standards for migration limits and chemical safety.
• Regulatory Compliance: The FSSAI and other food safety authorities globally assess plastics based on migration limits, chemical composition, and overall safety for food contact. For instance, a polycarbonate material will only be considered food- grade if it meets stringent criteria regarding BPA content and other potential contaminants.

Let's understand plastic food grade or non-food grade with example of PET plastic

To distinguish between a PET bottle used for food and one used for cleaning chemicals, and to establish whether a PET bottle is food- grade, the following aspects need to be considered:

* Establishing Food-Grade PET Bottles (IS 12252:1987):

• Raw Material selection: The resin used in food-grade PET bottles must be food-grade that indicates that the raw material complies with the required safety standards and is free from contaminants or additives that could pose a risk to health. • Absence of Harmful Additives: Food-grade PET bottles shall not contain any harmful additives or recycled materials that are not certified for food contact. This includes avoiding additives like plasticizers, dyes, or stabilizers that are not approved for food use.
• Migration Testing: Food-grade PET bottles must undergo migration testing to ensure that any substances that may migrate into the food remain within the safe limits set by BIS/FSSAI. The tests simulate conditions like high temperature, acidity, or prolonged storage to evaluate potential risks.

Key Parameters to be Considered for establishing Food- Grade PET Bottles (IS 12252:1987)

A. Chemical Composition:

a. Monomer Residuals:

i. Parameter: Check for residual monomers (e.g., ethylene glycol, terephthalic acid in PET) that may be present in the plastic.

ii. Food-Grade Requirement: Residual levels must be below the limits specified by BIS to avoid contamination of food.

b. Additives:

i. Parameter: Analyse the types and amounts of additives (e.g., plasticizers, stabilizers, colorants) used in the plastic.

ii. Food-Grade Requirement: Only BIS-approved additives, such as those listed in IS 9833, should be used. Non-food- grade plastics may use additives that are not safe for food contact.

B. Migration Testing:

a. Overall Migration Limit (OML):

i. Parameter: Test for the total quantity of substances that can migrate from the plastic into food.

ii. Food-Grade Requirement: The overall migration must be below 10 mg/dm2 of the surface area or 60 mg/kg of food simulant, as per IS 9845.

b. Specific Migration Limit (SML):

i. Parameter: Analyse specific substances that may migrate into food (e.g., heavy metals, specific additives). ii. Food-Grade Requirement: 

ii. Food-Grade Requirement: Each substance must be below its specified SML, as defined in the relevant BIS standards.

Food-grade plastics should maintain their integrity under conditions such as high temperatures, pressure, or mechanical stress.

A. Permeability:

i. Parameter: Measure the plastic's permeability to gases and moisture, which can affect the shelf life of the food.

ii. Food-Grade Requirement: Low permeability is preferred for food-grade plastics to prevent spoilage and contamination.

B. Organoleptic Properties:

i. Parameter: Assess any impact of the plastic on the taste, odor, or color of the food.

ii. Food-Grade Requirement: Food-grade plastics should not impart any undesirable taste, odor, or colour to the food.

C. Thermal Stability:

i. Parameter: Analyse the plastic's stability at different temperatures, especially during processing (e.g., microwave, boiling).

ii. Food-Grade Requirement: Plastics must not release harmful substances when exposed to typical food processing or storage conditions.

D. Transparency and Clarity:

i. Parameter: For PET and other transparent plastics, ensure that the material maintains clarity without additives that could compromise food safety.

ii. Food-Grade Requirement: Must meet optical quality standards without compromising on safety.

Non-Food Grade Plastics:

Non-food-grade plastics such as PET (IS 12252:1987, IS 14803:2000 etc) do not need to meet the stringent safety requirements outlined above. They may contain higher levels of residual chemicals, non-approved additives, and may fail migration tests. These plastics are not tested for food safety and should not be used in applications where they come into contact with food.

Let's understand how same plastic can be food grade and non-food grade.

Let's understand with polycarbonate (PC) as example of plastic, some types of polycarbonate (PC) can be food-grade, and the situation is more nuanced. The food-grade status of plastics, including polycarbonate, depends on the specific formulation, additives used, and whether they meet the relevant regulatory standards. Let's clarify and refine the information:

1. Polycarbonate (PC)-IS: 14971

• Uses: Commonly used for making reusable food containers, water bottles, baby bottles, and some food packaging materials.
• Reasons for Food-Grade Status (IS: 14971): 
• BPA-Free Versions: Concerns about Bisphenol A (BPA), which is used in the production of polycarbonate, have led to the development of BPA-free polycarbonate products. BPA-free polycarbonate is widely accepted for food contact applications, provided it complies with migration limits and other safety criteria.
• Regulatory Compliance: Polycarbonate can be considered food-grade if it meets specific safety standards set by regulatory bodies.
• Application-Specific: Polycarbonate is particularly valued for its impact resistance, clarity, and thermal stability, making it suitable for reusable food containers, water bottles, and other applications where durability and repeated use are important.

2. Non-Food-Grade Polycarbonate (IS 12866:1990, IS 1060:1990 etc):

• Uses: While food-grade polycarbonate exists, there are also formulations of polycarbonate that are not intended for food contact. These are typically used in industrial applications like electronics, automotive parts, and eyewear.
• Reasons for Non-Food-Grade Status:
• Presence of BPA: Older or specific industrial-grade polycarbonate materials may still contain BPA or other additives not approved for food contact.
• Different Additives: Non-food-grade polycarbonate might include additives that enhance properties like UV resistance or color stability, which may not be suitable for food contact.

Key Points on Non-Food-Grade Plastics:

Here are more nuanced considerations for identifying non-food- grade plastics:

• Formulations and Additives: The key difference between food-grade and non-food-grade plastics often lies in the specific formulations and additives used. Even a type of plastic generally regarded as food-grade can be non-food-grade if it contains non-approved additives or fails to meet regulatory standards for migration limits and chemical safety.
• Regulatory Compliance: The FSSAI and other food safety authorities globally assess plastics based on migration limits, chemical composition, and overall safety for food contact. For instance, a polycarbonate material will only be considered food- grade if it meets stringent criteria regarding BPA content and other potential contaminants.

Conclusion:

When considering whether a plastic is food-grade, it's essential to focus on its specific formulation, compliance with safety standards, and intended use. Polycarbonate, for instance, can be both food- grade and non-food-grade, depending on these factors. The presence of harmful chemicals, non-compliance with regulatory standards, or the inclusion of non-approved additives typically distinguishes non-food-grade plastics.

How Safe is it to repeatedly use of Food Contact Plastic?

Uncovering the Risks of Repeatedly Using Food-Grade Plastics for Food contact. Look at whether food-grade plastics can be used repeatedly and under what conditions:

Repeated Use of Food Contact Food Grade plastic depends up on following Factors

• Cleaning and Sanitization: Proper cleaning and sanitization are crucial for repeated use. Food-grade plastics should be washed with appropriate detergents and sanitized to prevent contamination.
• Temperature Resistance: Plastics vary in their ability to withstand heat. For example, some food-grade plastics are microwave-safe and can tolerate high temperatures, while others may degrade or release harmful substances if exposed to heat repeatedly.
• Physical Wear and Tear: Repeated use can lead to physical damage, such as scratches or cracks, which can pose risk of food safety and may compromise food safety. Regular inspection is necessary to ensure the integrity of the plastic.
• Chemical Stability: Food-grade plastics should resist chemical degradation and migration. However, over time and with repeated exposure to various substances, some plastics might degrade or release harmful chemicals.
• Regulatory Compliance: Ensure that the plastic continues to meet regulatory standards for food safety even after repeated use. Some plastics are specifically tested and approved for repeated food contact.

3. Best Practices for Repeated Use:

• Follow Manufacturer Guidelines: Always adhere to the manufacturer's instructions regarding the use, cleaning, and maintenance of food-grade plastics.
• Inspect Regularly: Regularly check the condition of reusable food-grade plastics for signs of wear, damage, or contamination.
• Avoid Extreme Conditions: Avoid exposing plastics to extreme temperatures, harsh chemicals, or prolonged direct sunlight, which can accelerate degradation.
• Use Designated Containers: Use containers specifically designed for repeated use to ensure they are made from materials that can withstand repeated exposure and cleaning.

Conclusion:

Food-grade plastics can be used repeatedly if they are properly maintained and meet safety standards. The suitability for repeated use depends on the specific type of plastic, its resistance to heat and chemicals, and adherence to proper cleaning and maintenance procedures. Regular inspection and adherence to manufacturer guidelines are essential to ensure continued safety and performance.

How do Food Business Operator get certificate that food contact plastic material is food-grade in India??

A Food Grade Certificate for food contact plastic is not issued by the Bureau of Indian Standards (BIS) or the Food Safety and Standards Authority India (FSSAI). However, since the Food Grade Certificate is a mandatory requirement under the FSS Act and the regulations made thereunder, it may be obtained from NABL-accredited laboratories that are notified by FSSAI, provided the test parameters are met.

Important Terminologies (FST)

Abattoirs

Types of slaughterhouses where animals are slaughtered for meat and offal. Abattoirs usually include lairage (a holding area for live animals), a slaughtering line and cold stores. Facilities for processing of by-products (blood, intestines, skins, fat, bristle, unusable waste products), and treatment of wastewater and air are often included.

Acceptable daily intake

A safety level for substances used as food additives. Usually calculated as 1/100th of the maximum dose of the substance that causes no adverse effects in appropriate test organisms. Abbreviated to ADI.

Acetic fermentation

The process by which acetic acid bacteria such as Acetobacter and Gluconobacter spp. metabolize an alcoholic substrate to form acetic acid, the main constituent of vinegar. Alcoholic substrates can be obtained from a variety of sources, such as fruits, vegetables and grain.

Acetobacter

Genus of Gram negative, strictly aerobic, rod-shaped acetic acid bacteria of the family Acetobacteraceae, that are capable of oxidizing ethanol to acetic acid. Occur on fruits and flowers. May be responsible for spoilage of beer and wines. Acetobacter aceti and A. pasteurianus are used in commercial production of vinegar.

Acesulfame K

One of the non-nutritive artificial sweeteners (trade name Sunett). A white crystalline powder, approx. 200 times sweeter than sucrose. Often blended with other sweeteners to give a more sugar-like taste and to mask aftertaste. Stable under heat, and moderately acid or basic conditions. Used in foods and beverages since 1983 and approved by >100 countries worldwide. Used in beverages, dairy products, preserves, bakery products, confectionery, salad dressings and breakfast cereals.

Acetaldehyde

Aldehyde, synonym ethanal. One of the common flavour compounds in many foods and beverages. May cause taints in some foods. Toxic at excessive concentrations.

Acetates

Salts or esters of acetic acid. Flavour compounds in many foods and beverages. May be used as preservatives.

Acetic acid

Member of the short chain fatty acids group, which occurs in a range of foods and beverages. May be one of the flavour compounds, or cause taints, depending on food or beverage type and the concentration at which it is present. Acetic acid is the main constituent of vinegar. It may be used for preservation or flavouring of foods.

Acetone

Smallest of the ketones, synonym propanone. Widely used as a solvent in food analyses, particularly for lipids and related compounds. Produced along with butanol and ethanol as a microbial fermentation product from unconventional feedstocks including food processing wastes.

Acetic acid bacteria

Any aerobic, rod-shaped Gram negative bacteria, e.g. Acetobacter spp. and Gluconobacter spp., capable of oxidizing ethanol to acetic acid. Occur on the surface of fruits, vegetables and flowers, and in soil. Used industrially in the manufacture of vinegar. May cause spoilage of beer and wines.

Acidification

Process by which the pH of a substance is decreased to below 7 making it acidic.

Acidity

The degree to which a substance or solution is acidic, being dependent upon the concentration of hydrogen ions. Level of acidity is expressed using pH.

Acidolysis

Esterification reactions of acids with esters. Used to produce structured lipids (e.g. acidolysis of tristearin with long chain fatty acids) or to modify the lipid composition of fats and oils (e.g. acidolysis of seal blubber oils with lauric acid and interesterification of butterfat with CLA). Catalysed by lipases or chemical catalysts.

Acid values

The level of free fatty acids present in lipids. The acid value, also known as the acid number, is determined by measuring the amount of KOH in milligrammes that neutralizes 1 g of the lipid. Acid values of fresh edible fats tend to be low and increase with storage as the glycerides present in the lipids break down to generate free fatty acids.

Acids

Chemical compounds which release hydrogen ions when dissolved in water, or whose H can be replaced by metal atoms or basic radicals, or which react with bases to form salts and water. Include both organic acids and inorganic acids. Inorganic acids may be used in food processing or cleaning of equipment. Organic acids of many types are constituents of a wide range of foods, both as natural constituents and as processing aids. Important types of organic acids in foods include fatty acids, amino acids and carboxylic acids.

Acoustics

Study of the physical properties of sound; also refers to techniques based on transmission, generation or reception of sound. Acoustic devices have been used to detect insects infestation of grain. Acoustics has also been employed in examining the structure of materials, e.g. pasta, and as the basis of non-destructive methods to determine the texture of foods, such as fruits, cheese and bakery products.

Acids resistance

Ability of organisms to withstand acidic conditions. Important for survival of microorganisms in acid environments such as the gastrointestinal tract and during fermentation of foods.

Acidulants

Organic acids used in foods to control pH and fulfil a variety of functions. Applications include preservation of meat products, flavour enhancement, prevention of discoloration in sliced fruits, and prevention of development of rancidity in oils and fats. Commonly used acidulants in the food industry include citric acid, acetic acid, propionic acid and lactic acid.
 

Acrylamide

Synonym 2-propenamide (C3H5NO). Member of the amides which is a neurotoxin and exhibits carcinogenicity in animal models. Formed in foods during thermal processing as a product of the Maillard reaction between asparagine and reactive carbonyl compounds, e.g. in reducing sugars. Forms gels of polyacrylamides on polymerization under specified conditions which are used for PAGE.
 

Actins

A family of multifunctional intracellular proteins, best known as a myofibrillar component of striated muscle fibres. They constitute about 13% of muscle proteins and are the major components of the Iband or thin filament of the sarcomere. Actins contain high levels of the amino acid proline. Imino-groups within proline contribute to the folding of actin molecules and result in formation of G-actin (globular actin). G-actin, a spherical molecule approximately 5.5 nm in diameter, constitutes the monomeric form of actin. In the presence of potassium chloride and ATP, Gactin polymerizes into long fibres of F-actin. Most vertebrate genomes contain numerous actin genes with high sequence homology in protein coding regions, but considerable variability in intron size and number. This genetic diversity can be utilized for livestock speciation and meat authenticity tests. Determination of actin content has been proposed as a means of calculating the meat content of meat products.
 

Activated carbon

Amorphous forms of elemental carbon, particularly charcoal, which have been treated, e.g. by acid or heat, to improve their powers of absorption. Used for a variety of food and industrial applications, including drinking water purification, decoloration of sugar solutions and sorption of residues of pesticides from wines.

Activation energy

Minimum energy required for a chemical reaction to proceed; the difference in energy between that of the reactants and that at the transition state of the reaction. Activation energy determines the way in which the rate of a reaction varies with temperature.

 

Active packaging

Packaging materials which have functions additional to their basic barrier action. Used for packaging a wide range of foods and beverages. Types of active packaging include: packs which adsorb ethylene to control ripening of fruits; packs which regulate moisture levels; packs which contain oxygen scavengers; packs which contain CO2 scavengers or generators; packs which release or absorb flavours or aromas; antimicrobial packaging (e.g. packs which release ethanol to control the growth of fungi); packs with special microwave heating properties; and packaging with monitoring systems (time/temp. exposure indicators or temp. control).

Additives

Ingredients added in low quantities to foods during processing for one or more specific purposes. These include prevention of chemical and microbial spoilage, enhancement of flavour or colour, improvement of nutritional values or as an aid to processing. The most common types of additives include preservatives, colorants, sweeteners, flavourings, emulsifiers, thickeners and stabilizers.

Active sites

Locations on the surface of catalysts at which reactions occur. On enzymes, substrates are bound at the active sites, the shape of the site being important for strong and specific binding to occur.

Adenine

Purine, synonym 6-aminopurine. Component base of nucleic acids, nucleosides and nucleotides.

Adenosine

Nucleoside of adenine and ribose, synonym adenine riboside. Constituent of nucleotides and nucleic acids