Recyclates in packaging: opportunities and challenges
Sustainability has long been a key factor in the cosmetics industry. More and more brands want to make their packaging more resource-efficient and are turning to recyclates, i.e. plastics made from post-consumer or post-industrial waste. But how safe and practical is the use of these materials in cosmetics really?
What are recyclates?
Recycled materials (also known as post-consumer recycled materials, PCR) are produced by processing used plastics. In the cosmetics sector, these are mostly polyolefins such as polyethylene (PE) and polypropylene (PP) or PET. These materials are collected, sorted, cleaned and reprocessed into packaging.
Advantages of recycled materials
– Sustainability and resource conservation: The use of recycled materials reduces the demand for fossil raw materials and promotes the circular economy.
– Reduction of CO₂ emissions: Life cycle analyses show that PCR packaging enables significant CO₂ savings compared to new plastic.
– Consumer acceptance: Consumers are increasingly paying attention to sustainability – recycled packaging increases brand appeal.
Future regulation: The planned European Packaging and Packaging Waste Regulation (PPWR) aims to introduce binding minimum recycled content requirements by 2030 and 2040 – early adaptation will secure competitive advantages.
Disadvantages and challenges
Contamination: Residues from printing inks, additives or previous fillings can remain in the recycled material. Potentially toxic substances such as phthalates, heavy metals or PFAS are particularly critical.
Migration risks: Cosmetic products often come into contact with skin or mucous membranes. Even the smallest particles or molecules can migrate and pose a risk. Toxicological testing, for example according to the CosPaTox approach, is therefore essential.
Sensory properties: The smell and colour of recycled materials can vary and affect the perception of products.
Technical limitations: Some recycled materials are less stable when exposed to oils, solvents or heat. Mechanical properties such as abrasion and surface smoothness must also be tested.
Restrictions for sensitive target groups: The use of PCR is currently only recommended to a limited extent for children’s cosmetics or products with high skin penetration.
Safety through standards and testing
The European consortium CosPaTox has developed strategies for this purpose.
Lists of substances of concern with limit values
Migration calculations and exposure scenarios
In addition, it offers toxicological assessments (e.g. Ames test for mutagenicity).
These approaches provide manufacturers with a basis for the safe use of PCR materials in cosmetic packaging.
Conclusion
Recyclates offer great potential for making the cosmetics industry more sustainable, both ecologically and in terms of regulatory requirements. At the same time, their use requires thorough risk analysis, specific material testing and close cooperation between packaging manufacturers, formulators and brands.
The decision for or against the use of recycled materials in cosmetic packaging depends on many factors – from product safety to consumer perception. Cosmacon provides comprehensive advice on the selection of suitable materials, risk assessment and the development of sustainable packaging concepts.
Literature:
https://cospatox.com/publication/