PFAS are now thought to be in the bloodstream of nearly every person across the globe.[1] The widespread contamination of drinking water and the health risks associated with PFAS are alarming and present a critical challenge for the food packaging industry.
Across the EU, a proposed ban on PFAS is expected to take effect in 2026 and, although the UK falls outside this scope, falling within our own UK REACH regime, pressure to regulate PFAS usage is growing with the second reading of the Poly and Perfluorinated Alkyl Substances (Guidance) Bill on 24th January. Consumer awareness is evidenced by the Royal Society of Chemistry’s forthcoming survey publication. According to initial analysis of the data, 77% of the UK population believe that “some, most or all PFAS present a significant risk to human health”, while “over three quarters (88%) say that the use of PFAS known to be toxic should be stopped immediately or subject to more effective controls.”[2]
PFAS materials are widely used in food packaging due to their exceptional performance, offering resistance to oil, grease, and water, outstanding durability, non-stick properties, and the ability to withstand high temperatures without degrading. Finding a direct replacement for PFAS presents challenges, given their ubiquity and relatively low cost - especially for a sector as price-sensitive as food. Oil repellence is particularly problematic, given the low surface tension of oils. That said, for many products - including single use food packaging - PFAS may be unnecessary if the product is overperforming. Here, reviewing specifications can help reduce reliance on PFAS chemicals.
In addition to addressing over-specification, switching from 2D to 3D thinking - combining different layers and materials rather than seeking a direct replacement - offers interesting potential. Innovative nonwoven construction, strategic material selection, and surface functionalisation indicate promising ways forward and at NIRI we have applied these principles to develop next-generation PFAS-free products. In one instance, developing a single-use, durable product, we removed the PFAS from a woven product, meaning that its oil repellence dropped dramatically. We applied an alternative PFAS coating, coupled with laminating the woven fabric to a lightweight nonwoven. Both approaches showed improvement, but neither matched the repellence of the PFAS-treated fabric. We modified the structure of the component fabrics, the coating application, and the laminate configuration. These refinements enabled us to create a PFAS-free composite with oil-repellent properties comparable to the original fabric. This approach highlights the potential, and the importance, of moving from 2D to 3D thinking rather than relying entirely on chemistry to address the PFAS challenge.
Public demand for regulation is growing and, for companies embracing the challenge, there is commercial potential. At NIRI, we believe that collaboration and pragmatism deliver the best results: the continued use of PFAS may not be necessary when performance is interrogated and over-specification addressed. Equally, a shift from 2D to 3D thinking can impact sustainability: re-evaluating a product’s design and considering how engineering a fibre or fabric system may contribute to performance and end-of-life management can present opportunities. Ultimately, such an approach - emphasising a circular approach to a product’s lifecycle and embracing corporate and social responsibility - can help companies capture greater market share where consumer pressure is a key driver for change.
Find out more about NIRI’s expertise in PFAS: www.nonwovens-innovation.com
[1] https://www.theguardian.com/environment/2025/jan/17/uk-failing-to-match-eu-in-fight-against-forever-chemicals-say-scientists
[2] https://www.rsc.org/news-events/opinions/2024/11-november/pfas-limits/