How to Shift Away from ‘forever PFAS’ in Packaging
PFAS (Per- and Polyfluoroalkyl Substances) are almost everywhere, from products to the environment due to their special chemical properties and, therefore, in the media no matter where you live or what channel you watch. PFAS carbon-fluorine bonds are among the strongest in chemistry, making them extremely resistant to degradation and highly interesting for many industrial applications. However, these so called “forever chemicals” don’t break down easily in the environment or the human body.
Due to health and environmental concerns, regulatory bodies like the FDA (Food and Drug Administration), EPA (Environmental Protection Agency), and the European Union are increasingly restricting or phasing out PFAS in materials that come into contact with food and other applications. This is no longer a niche concern - it’s a global shift. Let us find out more about PFAS-free* alternatives and how they can help to shift away from PFAS in heat-sealing applications. For engineers working in packaging, especially in food, medical, and consumer goods, this shift presents both challenges and opportunities.
PFAS materials are a large group of synthetic chemicals used in a wide range of industrial and consumer products for their resistance to heat, water, and oil. They are widely used in non-stick cookware, water-repellent clothing, stain-resistant fabrics, firefighting foams, industrial applications where strong chemical, temperature and mechanical resistance as well as non-stick surfaces are key.
Heat sealing is a process that joins two thermoplastic materials by applying heat and pressure, causing them to melt and fuse together. Once cooled, the materials create a strong, airtight, and watertight seal. This technique is widely used in various industries for packaging, manufacturing, and assembling products.
For heat-sealing, Polytetrafluoroethylene (PTFE), a well-known PFAS polymer, has long been the material of choice for heat sealing tapes due to its exceptional non-stick properties and thermal resistance. In many packaging operations, especially those involving plastic films, PTFE-coated fiberglass tapes are used to prevent sticking and ensure clean, consistent seals.
However, as PTFE is part of the broader PFAS family, industries need alternatives due to potential regulatory, health or environmental concerns. The challenge? PTFE’s performance is hard to match. But not every application needs its full capabilities. In fact, many packaging operations are over-engineered with PTFE when simpler, safer alternatives would suffice.
With the supply chain for PFAS-based materials becoming less reliable, the combination of regulatory and logistical challenges is accelerating the demand for high-performance, PFAS-free* heat sealing solutions especially in food, medical, and consumer packaging applications.
With state level actions where authorities have taken steps to ban or restrict the use of PFAS in food packaging and voluntary commitments by manufacturers to phase out the use of certain PFAS in food packaging, PFAS-free* alternatives are gaining serious traction in heat sealing applications.
PTFE tapes combine unique properties that – as of now – no other PFAS-free* material can offer. For some applications therefore, PTFE tapes remain the best option. For others where PTFE tapes might be over-engineered, PFAS-free* tape solutions are potential alternatives with sufficient performance with added regulatory and sustainability benefits.
These new tape solutions are designed to work in heat sealing machines that are not PTFE-based. They have shown good performance sealing bags for over 1,000 seals. As these developments are brand-new, your tape experts can be contacted to get samples first-hand.
There are multiple constructions for heat sealing tapes available including fiberglass reinforced, plastic film, aluminum, and custom coated constructions to meet different application needs and customer demands.
Looking ahead, a version that works under even higher temperatures with increased performance for demanding sealing environments will be launched in the coming months.
These examples show that a lot is happening to help manufacturers shift away from current PTFE tapes in heat sealing without compromising performance.
Waiting for a global ban is risky. Companies that act now can avoid supply chain disruptions, reputational damage, and costly retrofits. Those that delay may find themselves scrambling to comply. But there are several things you can do today:
- Audit Your Packaging Materials: Identify where PFAS are used and assess risk exposure.
- Trial Non-PFAS Alternatives: Contact your tape supplier for samples and performance data.
- Engage Your Compliance Team: Stay ahead of evolving regulations in your operating regions.
- Collaborate with Experts: Work with partners who understand both performance and regulatory landscapes.
Although PFAS are known as “forever chemicals”, their “forever use” in many applications appears to be coming to an end. PFAS-free* tape alternatives are engineered to work seamlessly in existing heat sealing machines. In testing, they’ve demonstrated reliable performance to help manufacturers shift away for the better.
PFAS may be “forever chemicals,” but their use in packaging doesn’t have to be. With viable PFAS-free* alternatives now available, the industry has a clear path forward. The question is no longer “if” but “when” - and the answer should be “now.”