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    Fast Food Companies Are Replacing One Toxic Chemical With Another

    Consumer Reports found high levels of chemicals called phthalates in many foods—and even higher levels of chemicals developed to replace them

    Little Caesars Classic Cheese Pizza, Moe's Southwest Grill chicken burrito, Wendy’s Dave’s Classic with Cheese cheeseburger Photos: Consumer Reports

    Consumer Reports recently tested 85 foods for chemicals called phthalates, which are used to make plastic, and found them in many of the samples. That’s alarming, since those chemicals have been linked to a range of health problems. But our test found something else that raised concerns, especially in the fast food category: even higher levels of several chemicals that have been developed to replace those phthalates.

    Researchers say that although little is known about these substitutes, some may pose similar risks. This phenomenon—industry replacing a dangerous chemical with a newer one that might not be any safer—is so common that it has its own name: regrettable substitution.

    In our tests, we found both phthalates and their replacements in many products, with the alternatives often at much higher concentrations. That was especially true for fast foods. For example, a chicken burrito with rice and beans from Moe’s Southwest Grill had 48 parts per billion (ppb) total phthalates—and 15,351 ppb phthalate substitutes. That’s 320 times as much. We saw similar patterns with a Dave’s single burger with cheese from Wendy’s, a Classic cheese pizza from Little Caesar’s, a Whopper with cheese from Burger King, and large french fries from McDonald’s. Read more about how CR tested foods for phthalates and bisphenols (PDF).

    More on the Health Risks of Plastic

    Why does this matter? Well, like other chemicals that industry has previously developed to replace their more toxic predecessors, phthalate alternatives such as DEHA and DEHT are being used before their long-term effects on human health are fully understood.

    Environmental health experts have seen this scenario play out before. It happened when research about the risks of BPA led to public outcry that prompted manufacturers to replace it with similar chemicals like BPS and BPF, while declaring their products “BPA free.” It’s happening now with phthalates, as growing awareness of their potential harms have led to increased use of alternative plasticizers.

    “When a spotlight is shined on a particular phthalate or bisphenol, the manufacturer quickly moves on to a first cousin chemical,” says Philip Landrigan, MD, a pediatrician and the director of the Program for Global Public Health and the Common Good at Boston College. “Oftentimes we have little or no information on the substitute, and this speaks to a much bigger problem: Chemicals are allowed to come on the market in this country with almost no premarket safety testing.” That gap is why safety advocates say regulators should apply the “precautionary principle” when new, related chemicals come on the market, and assume them to be unsafe until proved otherwise.

    And they say that potentially harmful chemicals should be regulated as classes rather than individually. For example, while the Environmental Protection Agency recently announced that it is considering placing limits on certain PFAS chemicals in drinking water, experts worry that still leaves out thousands of other related compounds that could pose similar risks.

    “Otherwise, regulators are just playing whack-a-mole as they try to keep up as industry creates new, potentially toxic chemicals, without adequate testing,” says Michael Hansen, PhD, a senior scientist at CR. “We need to get ahead of the problem, not play catch-up.”

    Replacement Plasticizer Chemicals in Fast Food

    CR tested 14 fast foods for both phthalates and similar chemicals developed to replace them. Less is known about the potential health risks of these phthalate replacements, but CR’s experts say they could pose similar dangers. In our tests, levels of these replacement chemicals were often much higher than the originals. (Packaging materials are listed with the foods, and phthalates and replacements are listed in nanograms per serving.)

    fast food

    Total
    Phthalates (ng/serving)*
    Total
    Phthalate Replacements (ng/serving)*
    Moe’s Southwest Grill
    Chicken Burrito (aluminum foil)
    1 Order
    24,330
    7,813,659
    Wendy’s
    Dave’s Single Hamburger Patty (varied)
    1 Sandwich
    19,520
    2,973,073
    Burger King
    Whopper With Cheese (paper)
    1 Sandwich
    20,167
    1,546,529
    McDonald’s
    French Fries (paperboard)
    Large
    5,538
    1,270,534
    Little Caesars
    Classic Cheese Pizza (cardboard box)
    1 Patty
    5,703
    581,510
    Pizza Hut
    Original Cheese Pan Pizza (cardboard box)
    10-Piece
    2,718
    417,436
    McDonald’s
    Chicken McNuggets (cardboard)
    8 piece
    8,030
    387,801
    Taco Bell
    Chicken Burrito (paper wrap)
    1 Order
    4,720
    359,688
    Wendy’s
    Dave’s Single Hamburger Patty (varied)
    1 Patty
    3,629
    193,407
    Burger King
    Classic French Fries (paperboard)
    Large
    8,512
    166,224
    Burger King
    Whopper Hamburger Patty (varied)
    1 Patty
    2,870
    135,325
    Wendy’s
    Crispy Chicken Nuggets (paperboard)
    10-Piece
    33,980
    133,330
    Burger King
    Chicken Nuggets (paper bag)
    8 piece
    19,782
    130,821
    Chipotle
    Chicken Burrito (aluminum foil)
    1 Order
    20,579
    109,817
    Wendy’s
    Natural-Cut French Fries (paperboard)
    Large
    8,876
    107,002
    McDonald’s
    Quarter Pounder With Cheese (cardboard)
    1 Sandwich
    9,956
    13,869
    McDonald’s
    Quarter Pounder Hamburger Patty (varied)
    4 oz.
    5,428
    6,931
    Domino’s
    Hand Tossed Cheese Pizza (cardboard box)
    1/8 Pie
    4,356
    4,152
    *Total phthalates includes the 10 phthalates we tested for: BBP, DBP, DiBP, DCHP, DEP, DEHP, DnHP, DMP, DiNP, and DNOP. Total phthalate replacements include DEHA, DEHT, and DINCH). We also tested for three bisphenols (BPA, BPS, and BPF), which are not shown in this chart.
    CR Fights to Get Plastic Chemicals
    Out of Our Food, 1998-2024
    June
    1998

    CR finds plasticizer chemicals called phthalates in some plastic wraps and cheeses, and asks the FDA to eliminate the chemicals from the food supply.

    May
    1999

    CR finds that BPA in plastic baby bottles can leach into infant formula and advises parents to throw away bottles that could contain the chemical.

    December
    2009

    CR finds BPA in nearly all 19 tested foods and calls on government agencies to eliminate the chemical in materials that come in contact with food.

    October
    2012

    CR praises the FDA for banning BPA in baby bottles and sippy cups but calls on the agency to also ban the chemicals in infant formula containers and food cans. The FDA does so the following year.

    August
    2023

    CR does not find BPA, lead, or certain phthalates in nine baby bottles but warns that related chemicals could still be present and cautions parents to consider using glass or silicone bottles.

    January
    2024

    CR finds phthalates and related chemicals in nearly all 85 foods tested and calls on the FDA to get the chemicals out of food.

    Editor’s Note: This article also appeared in the February 2024 issue of Consumer Reports magazine.


    Headshot of CRO author Lauren Kirchner

    Lauren Kirchner

    Lauren Kirchner is an investigative reporter on the special projects team at Consumer Reports. She has been with CR since 2022, covering product safety. She has previously reported on algorithmic bias, criminal justice, and housing for the Markup and ProPublica, and was a finalist for the Pulitzer Prize in Explanatory Reporting in 2017. Send her tips at lauren.kirchner@consumer.org and follow her on Twitter @lkirchner.