Focus on powder coatings: The coatings industry’s transition to PFAS/PTFE-free solutions

Tobias Niederleitner details Clariant’s efforts to offer PFAS- and PTFE-free alternatives to the coatings industry across sectors such as powder coatings, printing inks and industrial coatings

In today’s environmentally conscious landscape, the coatings industry is facing rising pressure to phase out per- and polyfluoroalkyl substances (PFAS), including polytetrafluoroethylene (PTFE). The regulatory landscape is driving a growing demand for more eco-friendly alternatives across various applications, from industrial coatings to coatings and inks for consumer goods such as food packaging. 

Navigating this rapidly evolving regulatory terrain can be daunting for companies throughout the supply chain. However, taking a proactive approach to replacing PFAS/PTFE with alternative solutions is quickly becoming imperative for businesses seeking to maintain a competitive edge and meet consumer expectations for more sustainable products. 

At Clariant, we recognise the urgency of this transition and have adopted a proactive, pro-safety, and pro-environment stance to support our customers in navigating this ever-changing landscape. Our dedicated research and development efforts have yielded several innovative PFAS-free solutions for liquid metal coatings, powder coatings, inks, and other applications, positioning us as a reliable partner for companies seeking to leave PFAS additives behind. 

Our PFAS-free additives offer equal, if not superior, performance to their PTFE-containing predecessors, with some having benefits of lower dosage requirements. Extensive testing has demonstrated that these PTFE-free alternatives are not only viable replacements, but also offer a safer and more sustainable solution for printing on packaging, metal coatings, and beyond. 

Printing inks

One of the standout features of Clariant’s PFAS-free additives is their cost-effectiveness in printing inks. Leveraging a differentiated biopolymer-based micronised wax, our solutions can achieve the same rub resistance performance as PTFE-containing products while requiring 30% to 50% less dosage. This translates into significant cost savings for manufacturers without compromising on performance. 

Table 1: Colour difference after 50 rub cycles in flexographic printing ink 

Table 1 demonstrates extremely low delta E values, resulting in 20% higher mechanical resistance compared to commercially available PE/PTFE blends. 

In addition to their cost-efficiency, our PTFE alternatives boast a range of benefits that make them an attractive choice for environmentally conscious companies, such as: 

• High mechanical and temperature resistance 
• Low coefficient of friction (COF) 
• Compliance with current and foreseeable regulatory requirements 
• Improved sustainability profile 

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Powder coatings

The transition to PFAS/PTFE-free solutions is part of the coatings industry’s broader sustainability journey. Powder coatings, in particular, have inherent environmental advantages over liquid coatings, due to their solvent-free formulations with almost zero volatile organic compound (VOC) emissions during application and curing. Their high transfer efficiency also minimises product waste.

Additionally, the industry continues to innovate on multiple fronts to further enhance its environmental profile. This includes developing bio-based resins from renewable feedstocks, enabling reduced energy consumption during curing, and improving reclamation processes to facilitate the re-use of overspray powder.

Coatings for metal cans must withstand scratches and markings, whether on store shelves or in the manufacturing facility. Traditionally, coatings containing PTFE-based additives were used to enhance mechanical durability and prevent abrasion of the cans. However, Clariant provides more eco-friendly alternatives to PTFE for can coatings. Our wax additives are derived from bio-based raw materials, yet still offer the necessary protection to prevent damage to cans. 

Table 2: Taber Abraser test of solvent-based polyester coating 

The data in Table 2 demonstrates that the renewable-based Ceridust™ 8330 from Clariant exhibits significantly improved mechanical resistance compared to competitor products. After 200 abrasion cycles, which simulates extended use, Ceridust 8330 shows only 1.4 mg coating weight loss. In contrast, the PTFE-based competitors lose almost 2 or 4 mg of the original coating weight at 200 cycles. This superior abrasion resistance, especially at higher cycle counts, indicates that coatings formulated with Ceridust 8330 can better withstand mechanical wear and have a longer service life. 

In the ever-evolving world of powder coatings, the pursuit of more environmentally friendly and high-performance alternatives is paramount. Clariant has introduced a groundbreaking PFAS/PTFE-free texturing agent, as well as slip and scratch additives, poised to transform the industry. 

This innovative solution offers an array of advantages, including:

• PFAS/PTFE-free composition 
• REACH compliance 
• Adjustable gloss levels 
• Universal fine texture capabilities for light and dark coatings 
• Slip adjustment properties 
• Improved scratch resistance 
• Extrusion aid functionality without extrudate swelling 

One of the key highlights of the texturing agent, Ceridust 8170 M, is its adaptability for use in both light and dark-coloured coatings, addressing a common limitation in the industry. Furthermore, it presents an opportunity for energy reduction of up to 10% compared to PTFE-containing products, contributing to saving resources and cost-efficiency goals. Notably, this texturing agent achieves these benefits without causing extrudate swelling, ensuring the consistency and quality of the final product. 

Picture 1: White hybrid powder coating with different dosage levels of PTFE-free texturing agent:

Without additive

2% Ceridust 8170

M 4% Ceridust 8170 M 

Picture 1 visually demonstrates the impact of adding Clariant’s PTFE-free additive at different dosage levels on the surface appearance and texture of a coating or product. At a 2% dosage of the PTFE-free additive, the surface appears glossy, however, it also exhibits some surface structure or texture. In contrast, at a 4% dosage of the PTFE-free additive, the surface takes on a deep matte finish, and the texture becomes finely textured or structured. 

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This visual representation highlights how increasing the dosage level of Clariant’s specialised PTFE-free additive can significantly alter the surface characteristics from glossy to matte, as well as impart different levels of surface texture or structure. Such effects can be beneficial for applications like coatings, plastics, or films where controlling surface gloss, texture, and friction properties is important for aesthetics or functional performance. 

The wax-based slip and scratch additives, like Ceridust, Licowax™ and Licocene™, provide an alternative to PFAS-containing products previously used for decades to lower the coefficient of friction and boost mechanical resistance. 

The phase-out of PFAS is part of a larger industrial shift towards more sustainable chemical alternatives, driven by evolving regulations and consumer preferences. The coatings industry’s proactive stance demonstrates a commitment to responsible product stewardship. 

Clariant has been an early adopter of tools and initiatives aimed at minimising hazards and risks. The company was one of the first to implement the hazard labeling system under the Globally Harmonized System (GHS) and has been an active participant in the U.S. Environmental Protection Agency’s Safer Choice programme since its inception. 

As the coatings industry continues its sustainability transformation, companies that embrace PFAS/PTFE-free solutions will be well-positioned to capitalise on the growing demand for more environmentally friendly products. Consumers can anticipate a future where the coatings surrounding them not only deliver outstanding aesthetic and functional qualities, but also provide assurance that their production has minimised the environmental impact and safeguards the planet. 

Clariant remains committed to supporting this transition through its innovative speciality chemical solutions. 

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