Abstract
About 10% of plastic products are recycled worldwide, highlighting the need for technology improvements based on deeper material understanding. In packaging, which holds the highest market share in plastics demand, odor and potential hazards remain critical barriers to high-quality recycling. Conventional characterization relies on chromatography with extensive sample preparation. A gas chromatography system equipped with thermal desorption and dual flame ionization and mass spectrometric detection (ATD-GC/FID-MS) was established to analyze recyclates directly, thereby accelerating technology adaptation and guiding follow-up analyses. For calibration and validation, liquid standards were introduced into TenaxTA-filled tubes via a packed column injector and compared to a loading rig. The injector exhibited losses for higher-molar-mass compounds and solvent-dependent signal shifts. A storage study on compounded recycled polypropylene stored under various conditions showed that samples not frozen in sealed containers should be analyzed within 30 days. Experiments with varying sample geometries demonstrated that higher surface-to-volume ratios increase volatile release and variability in results, highlighting the need for uniform shapes. Applying the method to recycled yogurt cups enables the identification and quantification of contaminants, facilitating optimization of the washing process. Overall, ATD-GC/FID-MS provides a rapid screening tool for recyclate quality control and supports the improvement of recycling technologies.