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PFAS—often called “forever chemicals”—are under unprecedented global scrutiny. With the EU’s Packaging and Packaging Waste Regulation (PPWR, 2025) banning PFAS in food-contact packaging starting August 2026, and the U.S. EPA PFAS Action Plan (2021–2024) tightening limits across industries, extrusion manufacturers are under pressure to replace fluoropolymer-based polymer processing aids (PPAs) with PFAS-free alternatives

Why is it necessary to eliminate PFAS in polymer extrusion?

Per- and polyfluoroalkyl substances (PFAS), a group of persistent endocrine-disrupting chemicals, and linked to cancer, thyroid disease, and reproductive issues. PFAS have been used in industry and consumer products since the 1940s. PFAS are ubiquitous in the environment due to their stable chemical structure. As so-called “forever chemicals”, they have been found in soil, water, and air.8 Additionally, PFAS have been found in a variety of products (e.g., nonstick cookware, stain-resistant fabric, firefighting foams), food, and drinking water, leading to almost universal exposure of the general population (>95%).
So, PFAS contamination has led to stricter rules on their use in polymer extrusion additives. For film, pipe, and cable manufacturers, traditional PPAs pose risks in both compliance and brand reputation.

Below are the specific regulatory changes and initiatives contributing to this transition, based on available information:

1. European Union (EU) Regulatory Actions:

• ECHA’s Proposed PFAS Restriction (2023): In February 2023, the European Chemicals Agency (ECHA) proposed a comprehensive restriction on per- and polyfluoroalkyl substances (PFAS) under the REACH regulation. The proposal targets a broad range of PFAS, including fluoropolymers used as polymer processing aids (PPAs). While the fluoropolymer industry is seeking exemptions, the regulatory direction is clear: restrictions are being driven by the environmental persistence and potential health risks of PFAS. The aim is to limit their manufacture, use, and placement on the market, thereby prompting industries to adopt PFAS-free alternatives.

• EU Chemicals Strategy for Sustainability: The EU’s strategy takes a holistic approach to managing PFAS risks, prioritizing the phase-out of harmful substances and fostering the development of fluorine-free alternatives, including those for polymer processing. This has accelerated innovation in PFAS-free PPAs, particularly to ensure compliance with food-contact and packaging regulations.

• European Union Packaging and Packaging Waste Regulation (PPWR) 2025: Published in the European Official Journal on January 22, 2025, the PPWR includes a ban on the use of PFAS in food-contact packaging starting August 12, 2026. The regulation aims to reduce the environmental impact of packaging and protect public health by restricting PFAS in packaging materials, including polymer processing aids used in plastic film extrusion. Furthermore, the PPWR emphasizes recyclability requirements—an area where PFAS-free PPAs provide a clear advantage—thereby further incentivizing the shift toward sustainable packaging solutions.

 2. United States Regulatory Developments

• EPA’s PFAS Action Plan (2021–2024): The U.S. Environmental Protection Agency (EPA) has implemented several measures to address PFAS contamination:

• Designation of PFOA and PFOS as Hazardous Substances (April 2024): Under the Comprehensive Environmental Response, Compensation, and Liability Act (Superfund), the EPA designated perfluorooctanoic acid (PFOA) and perfluorooctanesulfonic acid (PFOS)—key PFAS compounds used in PPAs—as hazardous substances. This increases transparency and accountability for cleanup and encourages industries to transition to non-PFAS alternatives.

• National Drinking Water Standard (April 2024): The EPA finalized the first legally enforceable drinking water standard for PFAS, aiming to reduce exposure for approximately 100 million people. This regulation indirectly pressures industries to eliminate PFAS from manufacturing processes, including PPAs, to prevent contamination of water sources.

• Toxics Release Inventory (TRI) Additions (January 2024): The EPA added seven PFAS to the TRI under the 2020 National Defense Authorization Act, requiring reporting for 2024. This increases scrutiny on PFAS-containing PPAs and incentivizes the adoption of PFAS-free alternatives.

• Resource Conservation and Recovery Act (RCRA) Proposals (February 2024): The EPA proposed rules to add nine PFAS to the list of hazardous constituents under RCRA, enhancing cleanup authority and further pushing manufacturers toward PFAS-free solutions.

• State-Level Bans: States like Minnesota have implemented bans on PFAS-containing products, such as cookware, signaling a broader crackdown on PFAS-based materials, including PPAs used in food-contact applications. Other states, including California, Michigan, and Ohio, have cited the lack of federal action as a driver for state-level PFAS regulations, further encouraging the shift to PFAS-free PPAs.

3. Global and Regional Initiatives:

• Canada’s Regulatory Framework: Canada has established strong regulations to reduce and control PFAS production and use, influencing global manufacturers to replace PFAS-based PPAs with fluorine-free alternatives.

• Stockholm Convention: The international dialogue on PFAS regulation, particularly for perfluorooctanesulfonic acid (PFOS) and related compounds, has been ongoing for over a decade. While not all countries (e.g., Brazil and China) fully restrict certain PFAS, the global trend toward regulation supports the adoption of PFAS-free PPAs.

• 3M’s Phase-Out Commitment (2022): 3M, a major PFAS manufacturer, announced it would cease PFAS production by the end of 2025, prompting a surge in demand for non-PFAS PPAs to replace fluoropolymer-based aids in industries like film and pipe extrusion

4. Food Contact Compliance:

Regulations from the U.S. Food and Drug Administration (FDA) and the European Food Safety Authority (EFSA) emphasize PFAS-free PPAs for food-contact applications.

5. Market & Industry Pressure

Beyond regulatory mandates, consumer demand for eco-friendly products and corporate sustainability goals are pushing brand owners and manufacturers to adopt PFAS-free PPAs. This is particularly evident in the packaging industry, where PFAS-free solutions are sought for flexible packaging, blown films, and cast films to meet market expectations and avoid reputational damage.

Industry Response: PFAS-Free PPAs

Major polymer additive suppliers like Silike, Clariant, Baerlocher, Ampacet, and Tosaf have responded by developing PFAS-free PPAs that match or exceed the performance of fluoropolymer-based aids. These alternatives help reduce melt fracture, die build-up, and extrusion pressure, while ensuring compliance with food-contact regulations and supporting sustainability goals.

For example, Silike SILIMER Series Polymer Extrusion Additives offers PFAS-free, fluorine-free solutions to overcome processing challenges. Designed for blown, cast, and multilayer films, fibers, cables, pipes, masterbatch, compounding, and more, it can enhance the processing performance of a wide range of polyolefins, including but not limited to mLLDPE, LLDPE, LDPE, HDPE, PP, and recycled polyolefins.

PFAS-free Polymer Processing Aid Key Solutions for Sustainable Extrusion

√ Enhanced Lubricity – Improved internal/external lubricity for smoother processing

√ Increased Extrusion Speed – Higher throughput with less die buildup

√ Defect-Free Surfaces – Eliminate melt fractures (sharkskin) and improve surface quality

√ Reduced Downtime – Longer cleaning cycles, shorter line interruptions

√ Environmental Safety – PFAS-free, compliant with REACH, EPA, PPWR and global sustainability standards

Opportunities for Extrusion Manufacturers

√ Compliance Readiness – Stay ahead of EU 2026 & U.S. 2025 deadlines.

√ Competitive Advantage – Position as a sustainable, PFAS-free supplier.
√ Customer Trust – Meet packaging brand owner & retailer expectations.

√ Innovation Edge – Use PFAS-free PPAs to improve product quality & recyclability.

Frequently asked questions (FAQ)

What are PFAS-free PPAs? → Polymer additives designed to replace fluoropolymer PPAs, without PFAS risks.

Are PFAS-free PPAs FDA and EFSA compliant? → Yes, solutions from Silike, etc. meet food-contact regulations.

Which industries use PFAS-free PPAs? → Packaging, blown film, cast film, cable, and pipe extrusion.

What is the impact of the EU PFAS ban on packaging? → Food-contact packaging must be PFAS-free by August 2026.

The phase-out of PFAS-based PPAs is no longer a possibility—it’s a certainty. With EU and U.S. regulations approaching, and consumer pressure mounting, extrusion manufacturers must transition to PFAS-free polymer processing aids to remain competitive, compliant, and sustainable.

Future-proof your extrusion process. Explore SILIKE PFAS-free PPAs today to optimize performance and compliance.

Contact Amy Wang (amy.wang@silike.cn) or visit www.siliketech.com to get your fluorine-free solutions for extrusion processes, including eco-friendly film aids and alternatives to fluoropolymer PPAs for fibers, cables, pipes, masterbatch, and compounding applications.