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Decoding the PFAS puzzle: what converters need to know

Learn how PFAS regulations are impacting converters and the plastics industry. Discover what PFAS are, why they're under scrutiny, and explore alternatives to PFAS-containing PPAs for compliance and efficiency in production.

The Difference In Polymer Films

Staying ahead of the competition requires converters to have a deep understanding of the materials used in production and the regulations that govern them. That’s why we want to talk about recent concerns and regulatory actions involving per- and polyfluoroalkyl substances (PFAS), and how this evolving situation can impact converters.

What are PFAS and why are regulators scrutinizing them?

The term PFAS refers to a large group of synthetic chemicals used in various consumer products for 70+ years, in polymers as well as other applications.¹

PFAS may leak into soil, water, and air over time, and due to their strong carbon-fluorine bond, these so-called “forever chemicals” don’t degrade easily in the environment.

There are more than 4,000 types of PFAS, the most common of which include perfluorooctanoic acid (PFOA), perfluorooctanesulfonic acid, (PFOS), and perfluorobutanesulfonic acid (PFBS).

PFAS also accumulates in the human body. The U.S. Centers for Disease Control and Prevention says PFAS exposure can increase the risk of some cancers, and cause liver damage, developmental issues, and other conditions in humans.²

Regulators and researchers are still working to better understand a number of questions about PFAS, including:³

How to improve detection of PFAS in the environment
Measuring how many people are exposed to PFAS
Determining how harmful PFAS is to humans
How to manage and dispose of PFAS

While U.S. sales of several PFAS compounds have been phased out over the past 15 years, research and regulatory pressure continue.

For converters, this could have implications for brand demands, compliance, and more.

The Link Between PFAS and PPAs

Converters commonly use polymer processing aids (PPAs) to promote more effective and efficient molding processes with higher output and profitability.

PPAs help converters improve the quality of their products and the efficiency of their production lines.

Traditional PPAs, many of which contain PFAS, bring numerous benefits, such as:

Reducing motor load
Lowering extrusion melt pressure
Minimizing or eliminating melt fracture at high outputs
Reducing die lip buildup

Download our detailed whitepaper analyzing how PPAs accomplish these goals.

While PPAs are an essential ingredient for many converters, some PPAs contain PFAS, which are resistant to heat, oil, stains, grease, and water. This makes PPAs popular for food packaging and other applications.

Fluoropolymers, which are a class of PFAS, are used in extrusion products, injection molding products, automotive components, and more due to their chemical resistance, thermal stability, and electrical insulation properties.⁴

One study found that the process of fluorinating plastic can generate PFAS, which can leach into the content of the packaging.⁵

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Regulatory action on PFAS

Following studies that had raised safety questions about certain compounds known as “long-chain” PFAS, the sale of these compounds in the U.S. ceased in 2011.

The U.S. Food and Drug Administration officially phased out remaining uses of long-chain PFAS for food packaging in 2016.⁶

The agency has since turned its attention to short-chain PFAS compounds, including 11 specific compounds containing 6:2 fluorotelomer alcohol (6:2 FTOH). Manufacturers of those compounds agreed to phase out sales for food-contact applications between 2021 and 2024.

”These restrictions are driving converters to search for potential PFAS-free PPAs,” said Brennan Wodrig, Technical Service Engineer at Shell Polymers.

The matter is far from finished, and it goes beyond food applications.

The U.S. Environmental Protection Agency made headlines in 2023 when it alleged that a Texas-based coating maker was creating PFAS compounds as a byproduct of its fluorination process for high-density polyethylene chemical containers, which could potentially contaminate drinking water.⁷

The company appealed the EPA order, questioning the scientific basis for the decision and arguing that the agency exceeded its regulatory authority. The company also argued that the order would impact 100,000 jobs in various supply chains and cause $40 billion in economic losses.⁸

Ultimately, a federal appeals court ruled that the EPA had overstepped its authority and that the company could continue using fluorine gas to strengthen the barrier properties of containers, even though the process unintentionally creates small amounts of PFAS.⁹

Industry Innovation on PFAS

Amid continued regulatory scrutiny of PFAS, a new industry sector has cropped up to provide PFAS-free processing aids for the plastics industry:

”It seems like every month somebody is coming up with an improved variation of the additive, so we’re always looking at those,” said Dan Moldovan, Technical Service Engineer at Shell Polymers. “We want to make sure what's in our polymer is state-of-the-art and the best technology.”

Competitors in the PFAs-free space include companies Ampacet, Mitsui Plastics, Ingenia, BP Polymers, and others.^{10 11 12 13}

A growing number of companies and brands are advertising their PFAS-free product offerings.¹⁴

“PPA manufacturers have been working to come up with innovative solutions that comply with stringent regulations while maintaining production efficiency,” Sustainable Plastics reported.¹⁵

Disagreement remains over how easy – or not – it is to replace PFAS for various applications, but regulatory pressure and public awareness are increasing demand from brands, executives said at a recent Society of Plastics Engineers conference, according to Plastics News.¹⁶

"I don't know how many brands are here [at the conference] but the few that I know, that I've worked with, they have already made up their minds for packaging — they told us to change," Roberto Nunez, director of market development at additive maker Baerlocher USA, said at the SPE conference. "They told that to film companies, to suppliers. You have no choice. The only question is how or [at] what cost."

Shell Polymers experts recently conducted a study comparing PFAS-free PPAs with an industry-standard fluoropolymer PPA. We also analyzed a 50-50 mix of traditional and next-gen PPAs. We found some promising results.

For example, most next-generation PPAs cleared melt fracture faster than traditional PPAs, and it took less time to purge from the extrusion system. That’s just one factor, however. Converters must also consider cost, compatibility, loading, and printability.

Possible limitations remain, such as differences in coating mechanisms, extruder output and stability, melt temperature and pressure deviations, and surface build-up.