Post-consumer contamination in high-density polyethylene (HDPE) milk bottles and the design of a bottle-to-bottle recycling process.

Six hundred conventional recycled HDPE flake samples, which were recollected and sorted in the UK, were screened for post-consumer contamination levels. Each analysed sample consisted of 40-50 individual flakes so that the amount of analysed individual containers was in the range 24,000-30,000 post-consumer milk bottles. Predominant contaminants in hot-washed flake samples were unsaturated oligomers, which can be also be found in virgin high-density polyethylene (HDPE) pellet samples used for milk bottle production. In addition, the flavour compound limonene, the degradation product of antioxidant additives di-tert-butylphenol and low amounts of saturated oligomers were found in higher concentrations in the post-consumer samples in comparison with virgin HDPE. However, the overall concentrations in post-consumer recycled samples were similar to or lower than concentration ranges in comparison with virgin HDPE. Contamination with other HDPE untypical compounds was rare and was in most cases related to non-milk bottles, which are <2.1% of the input material of the recycling process. The maximum concentration found in one sample of 1 g was estimated as 130 mg kg(-1), which corresponds to a contamination of 5200-6500 mg kg(-1) in the individual bottle. The recycling process investigated was based on an efficient sorting process, a hot-washing of the ground bottles, and a further deep-cleaning of the flakes with high temperatures and vacuum. Based on the fact that the contamination levels of post-consumer flake samples are similar to virgin HDPE and on the high cleaning efficiency of the super-clean recycling process especially for highly volatile compounds, the recycling process investigated is suitable for recycled post-consumer HDPE bottles for direct food-contact applications. However, hand-picking after automatically sorting is recommended to decrease the amount of non-milk bottles. The conclusions for suitability are valid, provided that the migration testing of recyclate contains milk bottles up to 100% and that both shelf-life testing and sensorial testing of the products are successful, which are topics of further investigations.