A joint study from Earth Action and rePurpose Global has quantified microplastic migration into food products, finding that 1,000 tonnes of microplastic and nanoplastics move from plastic packaging into food and drinks every year. PET bottles account for a third of this packaging-related exposure, though particles also come from various types of plastic that contact food.
The research shows that significant microplastic shedding occurs before products reach consumers. As Earth Action co-CEO Dr Julien Boucher explained, "A lot of loss happens even before the product enters the door. That could be during production, packaging, processing, or storage or delivery."
Two main factors drive exposure: consumer handling (storage temperature, UV exposure, pressure from squeezing or crushing) and manufacturing processes. Brands and manufacturers have limited control over how consumers treat packages, but can optimize their own operations. Design choices matter substantially. Continuous rings on bottles typically generate less microplastics than segmented ones, while larger pack formats are responsible for proportionally fewer microplastics. How well a package resists mechanical stress also plays a role.
Manufacturers can also influence supply chain conditions beyond their direct control. "Producers can influence how packs are stored and delivered," Boucher said. "You provide information to the key stakeholders to try and avoid the worst-case scenarios."
Boucher emphasized that companies have practical solutions available. "Emissions can go up very easily and very quickly if you don't make the right decisions," he said. "There are solutions in terms of design and in the supply chain that can make a big difference." Earth Action offers resources for companies to assess their operations, identify hotspots, and plan action to lower microplastic emissions.