Introduction

Retail giants and consumer goods companies have successfully marketed the “spout pouch” as a convenient feeding solution for parents on the go. These flexible plastic squeeze pouches have largely replaced traditional glass jars, with sales in the United States skyrocketing by approximately 900% between 2010 and 2023. However, this shift occurs amidst a global plastic pollution crisis, where production is set to more than double by 2050. Research suggests that infants and children experience significantly more microplastic exposure per kilogram of body weight than adults, and the dominance of plastic food packaging is a primary contributor to this risk.

Generation plastic: The baby food pouch boom

The global baby food market was valued at USD 84.31 billion in 2026 and is projected to exceed USD 100 billion by 2029. Flexible plastic spout pouches are the fastest-growing packaging format, expanding at a rate of 8.18% year on year. They are expected to comprise 37.15% of the 2025 global market by volume. In major markets like the United Kingdom and Australia, fruit and vegetable purees in pouches have become primary products. This growth is driven by consumer preferences for price and convenience, yet it reinforces a fossil fuel-dependent system that exacerbates climate change and biodiversity loss.

Plastics, microplastics and chemical additives

Plastic packaging is a complex mix of polymers and chemical additives that can shed microplastics and nanoplastics over time. Friction from opening twist caps or heat from warming pouches can increase the release of hazardous chemicals. These migrants include intentionally added substances (IAS) and non-intentionally added substances (NIAS), such as manufacturing by-products. These chemicals often create a “cocktail effect,” where multiple substances have additive or synergistic impacts that current safety assessments fail to predict. Many, including bisphenols and phthalates, are known endocrine-disrupting chemicals (EDCs) that interfere with hormonal development.

New research: Microplastics and chemicals in baby food

Testing commissioned by Greenpeace International in 2025 at SINTEF Ocean analysed Danone’s Happy Baby Organics and Nestlé’s Gerber products. The study found microplastics in all subsamples. For each gram of food, there were up to 99 microplastic particles in the Danone pouches and up to 54 particles in the Nestlé pouches. This is equivalent to an estimated total of more than 11,000 particles in each Danone Happy Baby Organics pouch and more than 5,000 particles in each Nestlé Gerber pouch. A link was identified between the polyethylene lining of the pouches and the microplastics found. Chemical analysis also tentatively identified 55 plastic-associated chemicals in the Danone product and 28 in the Nestlé product, including the hazardous chemical 2,4-di-tert-butylphenol (2,4-DTBP).

Broader scientific evidence: Microplastic and chemical migration in baby food packaging

Broader research reinforces these findings. Preparing infant formula in polypropylene bottles can release between 1 and 16 million microplastic particles per litre. One recent study calculated that just three minutes of microwaving a plastic baby food container could release up to 4 million microplastic particles, while another container released up to 2 billion nanoplastic particles per square centimetre of packaging. Furthermore, widespread detection of EDCs has been recorded in baby food materials, with BPA found in 30% of samples and the phthalate DEHP in 23%.

The vulnerability of babies to microplastics and chemicals

Infants are uniquely vulnerable because their brains, immune systems, and hormonal systems are still developing rapidly. Their detoxification systems, including liver enzymes and kidneys, are not fully functional in the first months of life, allowing toxins to circulate longer. Additionally, infants consume more food and drink per kilogram of body weight than adults; for instance, young children require three times more water per unit of body weight. This results in a much higher relative dose of contaminants, increasing potential health risks.

Plastics – Beyond the regulatory frontier

Regulation has not kept pace with the rapid expansion of plastic packaging. Current laws often focus on microbeads and glitter rather than the release of microplastics from food contact materials. While some jurisdictions have implemented bans, such as France’s 2025 ban on plastic food containers in schools, baby food pouches remain largely unregulated. The report notes that the “safe limits” used in European Union packaging law do not account for the “cocktail effect” or the specific vulnerabilities of developing infants.

Conclusions

The introduction of flexible pouches has transformed the global baby food market with minimal scrutiny of health impacts. Evidence suggests that these pouches are a significant source of microplastic and chemical exposure. Delaying action is considered unethical given the known risks to infant health and the natural systems that sustain human life.

Recommendations

The report advocates for a framework based on the Precautionary Principle, shifting the burden of proof to producers. Policymakers are urged to negotiate a UN Global Plastics Treaty that cuts production by at least 75% by 2040 and eliminates problematic plastics like PVC and polystyrene. Manufacturers and retailers should create plans to phase out plastic packaging, review internal testing protocols to include microplastics, and commit to full material disclosure. Greenpeace calls for a transition towards non-toxic, zero-waste, and reusable packaging systems to protect future generations.