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Plastic vessels and what "food-grade" actually means

Can I ferment cider in a plastic barrel, and how do I know it is safe?

In short

Plastic fermenters are usually high-density polyethylene, polypropylene or, for carboys, polyethylene terephthalate. All three are used throughout the food industry and none of them are a problem in themselves.

What matters is whether the specific container was manufactured for food contact, using approved polymers and additives, and whether it has only ever held food. A drum of the right polymer that previously held a chemical is not made food-safe by washing it.

The two real risks are taint carried by the plastic and oxygen crossing the wall over long storage. Both are manageable if the vessel is chosen and used with those risks in mind.

What "food-grade" means and how to check

Food-contact materials are regulated: in the UK and EU, plastics intended for food contact must comply with the relevant food-contact materials legislation, use only authorised substances, and be supplied with a declaration of conformity. Compliant containers usually carry a symbol of a glass and fork, or a statement of compliance, moulded or printed on them.

The moulded recycling triangle with a number in it is not a food-safety mark. It identifies the polymer for recycling purposes and says nothing about the additives, the pigments, the release agents or the previous contents. A drum marked with the polyethylene code may be perfectly suitable or entirely unsuitable, and the code cannot distinguish them.

Second-hand drums are the commonest source of trouble. A drum that held a food product — fruit concentrate, brine, olives, glucose syrup — and can be identified as such is normally fine after thorough cleaning. A drum whose previous contents are unknown, or which held anything non-food, should not be used, and no amount of scrubbing changes that: solvents and aromatic compounds partition into polyethylene and leach back out into an alcoholic liquid for years.

Taint

Polyethylene is a good solvent for many small organic molecules. That is the physical basis of plastic taint: compounds absorbed into the wall diffuse back into a liquid that is a better solvent for them than water is, and ethanol makes cider a much better solvent than the juice was. A container that smells of nothing when dry can taint a cider after months of contact.

The same mechanism means fermenters acquire a history. A plastic vessel used for a heavily hopped or spiced batch, or one that has held a spoiled cider, may carry that character forward. Serious users keep dedicated vessels for flavoured batches.

Scratches are the other issue. Polyethylene is soft, and every scrub with an abrasive pad leaves grooves that hold soil and organisms below the reach of a sanitiser. Plastic vessels are cleaned with soft cloths and chemistry, and are retired when the interior is visibly scored.

Oxygen through the wall

Polyethylene and polypropylene are permeable to oxygen. The rate is low, but it is not zero, and it scales with surface area and with time. For a primary ferment of a few weeks this is irrelevant — the carbon dioxide leaving the vessel vastly outweighs anything coming in. For maturation over a year it is not irrelevant, and cider held long-term in thin-walled plastic will oxidise measurably faster than the same cider in glass or steel.

The practical rule most producers arrive at is: plastic for fermentation and short-term holding, glass, steel or wood for extended maturation. Thicker-walled vessels and those with a barrier layer perform better, and an intermediate bulk container in a metal cage is thicker-walled than a thin food drum.

Light is a related consideration. Translucent white or natural polyethylene passes light, and cider is susceptible to light-induced changes. A vessel that lets light through belongs in the dark.

Choosing and fitting out a plastic vessel

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