Is Food Packaging Safe? A Practical Guide for Food Businesses

Packaging Vocabulary

The key concepts below are commonly used and discussed by regulators, scientists, and packaging suppliers. 

Food Contact Material (FCM)

Any material intended to come into contact with food, including packaging materials, coatings, adhesives, and printing inks.

Food-Grade

An industry term suggesting a material may be suitable for food contact under certain conditions. It is not a standalone safety guarantee.

Migration

The transfer of small amounts of substances from packaging into food, influenced by factors such as food type, temperature, and contact time.

Functional Barrier

A layer in packaging designed to limit or prevent migration into food.

Multi-Layer Packaging

Packaging made from two or more bonded materials, often used to improve barrier performance.

Recyclability Claim

A statement that packaging is recyclable, subject to accuracy requirements such as California’s SB 343.

Safeguard Our Health Through Material Selection

Food packaging safety frameworks are designed to safeguard human health by limiting exposure to substances that may migrate from packaging materials into food. This principle applies not only to base polymers or paper substrates, but also to inks, coatings, adhesives, and additives used throughout the packaging system.

Regulatory authorities do not assess packaging materials in isolation. Instead, they evaluate whether substances used in packaging are likely to become components of food under intended conditions of use, and whether the resulting exposure remains within established safety thresholds. In both the United States and the European Union, this evaluation is grounded in toxicological data, estimated dietary exposure, and realistic use scenarios rather than assumptions about material inertness.

Even materials commonly used in food packaging may behave differently depending on food type, temperature, and contact duration. For this reason, packaging safety depends on material selection, formulation control, and appropriate use conditions rather than broad claims such as “safe” or “non-toxic.”

Independent scientific organizations such as the Food Packaging Forum emphasize that packaging safety is best understood as a system-level assessment, where polymers, inks, and coatings are evaluated together for their potential contribution to overall exposure. 

Does “Food-Grade” Alone Define Packaging Safety?

The term “food-grade” is widely used in packaging discussions, yet it does not have a single, globally consistent definition across regulatory systems. Food packaging safety is therefore not determined by a label alone, but by how materials are evaluated for their intended contact with food and their potential to transfer substances into it.

In the United States, the U.S. Food and Drug Administration (FDA) defines food contact substances as materials that are reasonably expected to become components of food as a result of their use in manufacturing, packaging, transporting, or holding food. This definition includes not only the primary packaging material, but also substances such as adhesives, colorants, coatings, and printing inks used as part of the packaging system.

In the European Union, the European Food Safety Authority (EFSA) explains that food contact materials include all materials and articles intended to come into contact with food, and that chemicals may transfer from these materials into food during use. 

As a result, a packaging material described as “food-grade” may still require additional context, documentation, and evaluation to determine its suitability for a specific food application.

What “Food-Grade Paper” Means?

Paper is often perceived as a natural or inherently safe packaging material, particularly for food applications. However, the designation “food-grade paper” does not refer to a single, uniform standard and should be understood within a broader safety context.

Food-grade paper typically refers to paper manufactured under controlled conditions suitable for specific food-contact uses. Regulatory assessments consider not only the paper fibers themselves, but also substances used during processing, such as sizing agents, surface treatments, coatings, and printing-related components.

One important consideration is whether paper contains recycled fibers. While recycled paper may be appropriate for certain food-contact applications, it can also introduce contaminants if not properly managed. Another factor is the use of optical brighteners (fluorescent whitening agents), which may improve visual appearance but are not always suitable for food-contact uses.

In the European Union, food contact paper and board fall under the general food contact materials framework, which requires that materials do not transfer constituents to food in amounts that could endanger human health. 

Food-grade paper should therefore be evaluated based on manufacturing controls, intended food contact, and supplier documentation rather than assumed to be safe by default.

Controls on Coatings, Optical Brighteners, and Microbial

Packaging materials often rely on coatings and surface treatments to achieve functional performance, such as grease resistance, moisture protection, or improved durability. These treatments are included in food packaging safety evaluations because they can influence migration behavior.

Coatings applied to paper or plastic packaging may contain polymers, additives, or curing agents that require assessment. Optical brighteners used to enhance whiteness are also reviewed, particularly for paper-based packaging intended for food contact.

Microbiological considerations are especially relevant for paper materials, which can absorb moisture more readily than many plastics. Manufacturing hygiene and good manufacturing practices (GMP) help reduce risks associated with microbial growth during production and storage.

Regulatory frameworks emphasize that coatings, additives, and microbial controls should be evaluated as part of the overall packaging system rather than treated as secondary concerns. 

EVOH in Food Packaging: Barrier Performance and Labeling Considerations

Ethylene vinyl alcohol (EVOH) is widely used in food packaging as a high-performance oxygen barrier. It is commonly incorporated into multi-layer structures to extend shelf life by reducing oxygen transmission.

From a food safety perspective, EVOH is evaluated based on migration behavior and its role within a multi-layer structure. When properly designed with functional barrier layers, EVOH can support both product stability and safety.

EVOH is sometimes discussed in relation to recyclability and labeling, particularly in California. California’s SB 343 (Truth in Labeling for Recyclable Materials) does not regulate EVOH as a food-contact material. Instead, it addresses the accuracy of recyclability claims made on packaging labels.

Under SB 343, packaging labeled as “recyclable” must meet specific criteria related to collection, sorting, and processing. Multi-layer structures that include barrier materials such as EVOH may affect whether such claims can be substantiated. 

This case shows the importance of evaluating food packaging safety separately from material production considerations, while also accounting for practical environmental labeling requirements.

How Temperature During Shipping, Storage, and Use Affects Packaging Safety

Temperature is one of the most important factors influencing packaging safety and performance, and its impact extends beyond the point of final use. Packaging materials are exposed to a range of temperature conditions throughout their lifecycle, including shipping, storage, and consumer handling.

From a business perspective, packaging may be stored in warehouses without climate control or transported across regions with significant seasonal variation. Shipping containers and delivery vehicles can experience elevated temperatures, particularly during warmer months. Prolonged heat exposure can affect material flexibility, seal strength, and, in some cases, increase the likelihood of chemical migration. Cold exposure during winter shipping or freezer storage can have the opposite effect, causing certain plastics to become brittle and increasing the risk of cracking or seal failure.

From the consumer side, packaging is often used beyond its original design intent. A pouch designed for dry coffee beans may be exposed to hot liquid if it is used to hold or stir freshly brewed coffee. Similarly, packaging intended for refrigerated foods may be placed directly into freezers, or materials designed for room-temperature storage may be reheated or microwaved.

For this reason, packaging materials are evaluated based on specific temperature ranges and contact conditions. Packaging that performs well at room temperature is not automatically suitable for freezer storage or contact with hot liquids. Materials intended for frozen foods, hot-fill products, or microwave use are typically selected and tested with those conditions in mind.

Practical takeaway: temperature considerations should account for shipping, storage, and expected consumer use, not just the point of sale.

Use Cases: Pouch Packaging in the Food Industry

Flexible pouches are widely used in the food industry due to their lightweight design, customization potential, and suitability for low-MOQ production. Different food applications, however, place different demands on pouch materials.

For dry foods, such as snacks or powders, packaging often prioritizes moisture protection and print performance. Paper-based or mono-material plastic structures may be suitable when inks and coatings are evaluated for indirect food contact.

For fatty or oxygen-sensitive foods, multi-layer pouches with oxygen barrier layers, including EVOH, are commonly used to reduce oxidation and preserve quality. In these cases, barrier performance and migration behavior are key safety considerations.

For liquids and sauces, pouches must withstand longer contact times, higher moisture exposure, and sometimes elevated temperatures during filling. Material structure, seal integrity, and adhesive performance are therefore closely evaluated.

Across these use cases, food packaging safety assessments focus on matching material performance to food type and use conditions rather than applying a single structure universally.

Top Chemicals of Concern & How Dylign Address Them

Regulatory reviews and scientific studies highlight several groups of chemicals that can migrate from packaging into food. Knowing which compounds matter most and how they can be avoided. We are here to provide product but also, to help brands choose safer materials.

1. Phthalates (plasticisers)
   Phthalates are used to soften PVC and other plastics. Migration of these compounds has been detected from various types of packaging, and food is thought to be a major exposure source. Some phthalates, such as DEHP, DBP and DIBP, are linked to reduced fertility and other reproductive‑toxic effects. Because of these risks, the European Union has restricted their use in food contact materials.
   What to do: Choose phthalate‑free films and adhesives, avoid PVC when possible, and use barrier layers that reduce migration.

2. Bisphenols (BPA and related compounds)
   Bisphenol A (BPA) and its analogues are used in polycarbonate plastics and epoxy coatings. Studies on reusable plastic foodware show that bisphenols can migrate into food, and these chemicals have endocrine‑disrupting properties.
   What to do: Opt for BPA‑free and bisphenol‑free resins, use water‑based or UV inks that do not rely on bisphenol derivatives, and request migration test data from suppliers.

3. PFAS (per‑ and polyfluoroalkyl substances)
   A 2024 review identified 68 different PFAS in food contact materials; most are not listed in regulatory inventories, and hazard data exist for only a few. PFAS are persistent and can accumulate, and there is a move toward banning them in packaging: the US FDA has announced a phase‑out of PFAS in grease‑proofing agents, and the EU is preparing a ban.
   What to do: Select PFAS‑free coatings and grease‑resistant papers; compostable and recyclable pouches with natural barrier chemistries offer oil resistance without fluorinated compounds.

4. Mineral‑Oil Hydrocarbons (MOSH/MOAH)
   Recycled paper and board can contain mineral‑oil saturated hydrocarbons (MOSH) and mineral‑oil aromatic hydrocarbons (MOAH). MOAHs have mutagenic and carcinogenic properties, and MOSHs accumulate in human tissues. High migration levels of MOSH and MOAH have been measured in foods packaged with recycled paperboard.
   What to do: Use mineral‑oil‑free inks and adhesives; add internal bags or functional barrier films to block migration; and consider virgin‑fiber paper for direct food contact.

5. Heavy Metals (lead, cadmium, mercury, hexavalent chromium)
   Many US states prohibit intentional use of these metals in packaging and limit incidental concentrations to 100 parts per million. Guidelines for food contact articles also emphasise testing for metals like nickel and cadmium.
   What to do: Ensure pigments, inks and coatings are free of these metals; verify compliance with state and EU limits; and request Certificates of Compliance from suppliers.

6. Other concerns: volatile additives and microbial safety
   Volatile organic compounds (VOCs) and additives from inks and coatings can migrate if not properly formulated, and paper materials can absorb moisture and support microbial growth.
   What to do: Choose low‑migration inks and coatings, ensure manufacturing hygiene through Good Manufacturing Practices, and source packaging from facilities with robust sanitation controls.

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