Food packaging materials can release chemical compounds that migrate into food products, potentially affecting safety and quality. Current testing shows migration levels ranging from 0.01-10 mg/kg for plasticizers, printing inks, and adhesive components, with rates accelerating at elevated temperatures and in the presence of fatty foods. Understanding these interactions requires precise measurement across multiple time scales and environmental conditions.

The fundamental challenge lies in developing testing methodologies that can accurately simulate real-world storage conditions while providing results within commercially viable timeframes.

This page brings together solutions from recent research—including thermal aging protocols for shellac barrier coatings, polyurea adhesive systems designed for minimal migration, innovative laminate structures with decomposition gas adsorbents, and liquid-repellent coating technologies. These and other approaches help manufacturers validate packaging materials against regulatory standards while maintaining product quality throughout shelf life.

1. Crosslinked Shellac Resin Coating for Molded Pulp Products

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE, 2024

A food-grade barrier coating for molded pulp products like bowls, trays, and containers that provides water and grease resistance. The coating is made by crosslinking shellac resin applied to the pulp. The crosslinking involves thermal aging in an oven to melt and fuse the shellac chains. This creates a durable, water-repellent coating that penetrates the pulp fibers. The coated pulp products have low cobb (water absorption) and kit (grease penetration) values, making them suitable for food packaging. The crosslinked shellac barrier meets food migration limits at elevated temperatures.

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2. Electron Beam Curable Coating Composition for Food Packaging with High Molecular Weight Acrylates and Urethane Acrylates Containing Isocyanate Groups

ARTIENCE CO LTD, 2024

Electron beam curable coating composition for food packaging materials that provides improved migration and water resistance compared to traditional electron beam curable coatings. The composition contains a high percentage (70% or more) of acrylate components with a molecular weight over 500, and a lower percentage (2.5-25%) of urethane acrylate components with an isocyanate group. This composition reduces migration by eliminating low molecular weight acrylates, while the high molecular weight acrylates provide water resistance. The isocyanate-containing urethane acrylates further enhance water resistance. The composition can also contain finely dispersed resin particles, leveling agents, silica, and other additives.

3. Laminated Packaging Film with Stretched Recycled Polypropylene Core and Gas Barrier Layer

TOYO SEIKAN KAISHA LTD, 2023

Laminated packaging film made from recycled polypropylene (R-PP) that addresses the issue of recycled PP having odor and degradation issues. The film has a stretched R-PP layer sandwiched between a sealant resin layer and a gas barrier layer. The gas barrier layer prevents odor migration from the R-PP to the sealed product. It can be an inorganic vapor deposited film or a gas barrier resin like ethylene/vinyl alcohol copolymer.

4. Multilayer Film with Inner Layer Composition for Reduced Degradation Product Migration

BERRY GLOBAL INC, 2023

Multilayer films for wrapping products that reduce migration of degradation products like nonylphenol from the film into the wrapped product. The films have an inner layer and an outer layer. The inner layer is formulated to reduce degradation and migration of degradation products compared to conventional inner layers. This prevents migration of degradation products into the wrapped product even if it doesn't directly contact the inner layer. The outer layer provides barrier properties. The inner layer composition can include a lower concentration of tris(nonylphenyl) phosphite (TNPP) compared to conventional inner layers, as well as other components that reduce degradation and migration.

5. Multilayer Food Packaging Film with Recycled Polyethylene Core and Barrier-Enhanced Virgin Polyethylene Outer Layers

TRIOWORLD LANDSKRONA AB, 2023

Multilayer film for food packaging that reduces migration of impurities from recycled polyethylene. The film has an inner layer of recycled PE containing impurities surrounded by virgin PE outer layers with barrier additives to prevent migration. This allows using lower quality, impurity-containing recycled PE in the core layer while still meeting food safety requirements due to the barrier layers. The barrier additives can be mica, talc, COC, or zeolite.

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6. Multilayer Food Packaging Films with Discontinuous Layer Cavities and Controlled Active Substance Migration

CAMPBELL SOUP CO, 2022

Multilayer food packaging films with migratory active substances that can release compounds into the food or surroundings. The films have discontinuous contact between some layers forming cavities. The layers are directly bonded by welding. The same thermoplastic polymer is used in all layers. This allows controlled release of active substances by tuning permeability through the layers using additives. The cavities disrupt diffusion paths. By using cavities and targeted additives, active substances can selectively migrate through certain layers and release more on one side versus the other.

7. Multilayer Packaging with Biodegradable Inner Layer and Polystyrene Outer Layer

TOTAL RES & TECHNOLOGY FELUY, 2021

Multilayered packaging materials for food applications that reduce migration of potentially harmful substances into the food. The packaging has a multilayer structure with an inner layer made of a biodegradable polymer like PLA and an outer layer made of polystyrene. The inner layer contacts the food. This configuration reduces migration of styrene and ethylbenzene from the polystyrene into the food compared to using pure polystyrene packaging. The biodegradable inner layer also adds renewable content to the packaging. The multilayer structure can be produced by coextrusion and the packaging can be thermoformed into containers.

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8. Polystyrene Food Packaging Incorporating Halloysite Nanotubes for Styrene Oligomer Catalysis

SIAMP CEDAP REUNIES, 2021

Food packaging made of polystyrene with low styrene migration to prevent contamination of the food. The packaging contains a specific type of clay called halloysite, present in nanotube form, in an amount of 0.1-50% by weight relative to the packaging material. The halloysite catalyzes the formation of styrene oligomers from monomers, dimers, and trimers, preventing their migration into the food.

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9. Multilayer Packaging with Recycled Resin and Dual Ethylene-Vinyl Alcohol Copolymer Barrier Layers

KURARAY CO LTD, 2021

Multilayer packaging structure with improved barrier properties and odor suppression for recycled materials. The structure contains a recycled resin layer, a polyolefin layer, and multiple ethylene-vinyl alcohol copolymer (EVOH) barrier layers. The EVOH layers are positioned inside and outside the recycled layer. This configuration reduces migration of low SP value compounds from the recycled layer. It also improves bending resistance compared to aluminum or nylon barriers. The compound with lower SP value than EVOH is preferably an aliphatic or aromatic hydrocarbon.

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10. Flexible Packaging Adhesive with Flexibilized Polyisocyanate Prepolymer and Polyaspartate Compound

COVESTRO LLC, 2021

Flexible packaging adhesive formulation and laminated films that avoid aromatic amine migration. The adhesive uses a flexibilized polyisocyanate prepolymer and a polyaspartate compound to provide mechanical strength and cure speed. The prepolymer has an aliphatic isocyanate and polyol with NCO content of 3-25%. The polyaspartate has an amine-terminated polymer. This adhesive can be applied to packaging layers and cured quickly without extended storage times compared to aromatic isocyanate adhesives. It eliminates aromatic amine migration issues when packaged food is sterilized.

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11. Food Packaging Standards for Plastic Material Selection and Safety Evaluation

RAHUL JAIN, 2020

The role of standards in food packaging, especially with regard to plastics, is to provide guidance on selecting suitable materials for food contact applications. It ensures that the plastics used are safe and do not pose any harm to human health or the environment. Standards also provide specifications for testing and evaluating the safety and suitability of plastics for food packaging. By adhering to these standards, food packagers can ensure that their packaging materials are safe for food contact and meet regulatory requirements.

12. Layered Packaging Film with Polyethylene Inner Layer for Additive Migration Control

AICERO CO LTD, 2019

Film for packaging food and pharmaceuticals that reduces contamination by preventing migration of additives like antioxidants into the packaged product. The film has a specific layered structure with an inner layer made of a specific type and density of polyethylene to minimize additive migration. The inner layer contacts the packaged product. The other layers contain additives like antioxidants but have thinner gauges to prevent migration. This prevents additives from leaching into the product while maintaining barrier properties.

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13. Multi-Layer Barrier Coating on Recycled Plastic Packaging with Plasma-Activated Cross-Linked Polymers and Amorphous Compounds

PLASMA ELECTRONIC GMBH, 2019

Coated packaging containers made from recycled plastic that prevent migration of unknown impurities from the recycled plastic into the packaged contents. The coating is applied to the recycled plastic surface using a non-specific barrier coating process. The coating consists of multiple layers: a first layer of randomly cross-linked polymers generated in a plasma, followed by a second layer of amorphous oxides, nitrides, fluorides, sulfides, or carbides. These layers create a dense barrier that prevents diffusion of migrating impurities from the recycled plastic. The barrier coating is applied using plasma activation and has a defined barrier efficiency.

14. Recyclable Food Packaging Film with Dual-Layer Polyolefin and Paper Structure

VERPA FOLIE WEIDHAUSEN BAUMANN GMBH & CO KG, 2018

A simplified, recyclable food packaging film that reduces migration of mineral oil hydrocarbons into packaged food. The film has a reduced layer structure compared to traditional barrier films. It contains only two layers: a polyolefin inner layer and an outer layer made of paper or paper coated with a polymer. This eliminates the need for adhesion promoters between dissimilar materials. The simplified film construction prevents or significantly reduces migration of saturated and aromatic mineral oil hydrocarbons, like MOSH and MOAH, into packaged food compared to complex multilayer barrier films.

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