Single-use plastic packaging, from cling film to flexible bags for chips or takeaway food containers, is generated in large volumes, but quickly ends up in municipal waste streams.

The problems posed by single-use plastic packaging are forcing legislative and regulatory bodies worldwide to adopt mandates and guidelines aimed at increasing the sustainability of single-use packaging. For example, the European Commission recently adopted the Packaging and Packaging Waste Regulation (PPWR), which requires all packaging to be recyclable and to contain a minimum percentage of recycled content for plastic packaging, among other provisions. Prior to the PPWR, the European Union adopted the Single-Use Plastics Directive (SUPD), which banned certain single-use plastic items for which non-plastic alternatives exist, such as cutlery, plates, straws, and expanded polystyrene food containers. In the United States, where 47% of plastic waste comes from single-use products and packaging, various states and municipalities are introducing bans on certain single-use plastic items, such as bags and straws.

Thanks to these regulations, many companies are switching to paper and fiber packaging, such as molded fiber and recycled paper packaging. However, this shift raises some challenges, given the historical use of PFAS (per- and polyfluoroalkyl substances) in food contact applications, particularly in paper and molded fiber packaging. This article will explore the intersection of sustainable packaging and PFAS, which is analyzed in depth in the IDTechEx report, "Per- and Polyfluoroalkyl Substances (PFAS) 2024: Emerging Applications, Alternatives, Regulations.".

Typical use of PFAS in food packaging

PFAS have been used historically since the 1950s in food contact packaging applications, particularly in compostable paper and molded fiber packaging, in coatings that impart oil and grease repellency. Such coatings can be found in:
takeaway boxes (e.g., pizza boxes) and clamshells
; baking paper and muffin tins
; takeaway cups
; microwaveable potato chip and popcorn containers
; and fast food paper wrappers.

The primary function of PFAS is to act as a barrier or repellent against grease, stains, and water. This barrier limits the migration of grease and water from the food to the packaging during transport, storage, and consumption. Previously, long-chain PFAS such as PFOS (perfluorooctane sulfonate) were used in food contact applications. With growing concerns about long-chain PFAS, many manufacturers of PFAS for food contact applications switched to short-chain PFAS, such as fluorotelomer alcohol 6:2 (FTOH).

Increased regulatory measures on PFAS in food packaging

Until recently, the use of PFAS in food contact applications was permitted in many major markets, including the US and the EU. However, growing concerns about human exposure to PFAS have led to an increase in regulatory measures specifically targeting PFAS in food contact applications; most of these regulations have been passed in the last 5–6 years. For example, in 2020, the US Food and Drug Administration announced the voluntary phase-out of 6:2 FTOH in food packaging applications by 2023. That same year, Denmark banned PFAS coating products for paper and cardboard food packaging. More recently, in 2024, the EU PPWR banned all food contact packaging containing PFAS above a certain concentration.

Finding alternatives to PFAS in sustainable food packaging

The concurrent trends of phasing out both single-use plastic packaging and PFAS-based packaging coatings are creating both an interesting challenge and an opportunity. The move away from single-use plastic packaging is driving increased use of paper and fiber packaging, which historically relied on PFAS-based coatings that are now being phased out in major markets. This presents an opportunity for both packaging and coating companies to develop non-plastic, PFAS-free packaging solutions.

Some long-standing manufacturers of PFAS for food packaging applications, such as Daikin America, have already developed PFAS-free polymer coatings for paper and fiber packaging. However, a key challenge for polymer coatings in food packaging applications is their impact on recyclability. Another problem with PFAS-based coatings, unrelated to their health effects, was that they negatively impacted the recyclability of the packaging that used them; polymer-coated paper and laminates are frequently sent to landfills for this reason.

Therefore, alternatives are needed to replace PFAS in coatings while maintaining the recyclability of paper and fiber packaging. The IDTechEx report, “Per- and Polyfluoroalkyl Substances (PFAS) 2024: Emerging Applications, Alternatives, Regulations,” highlights emerging alternatives that address these requirements, including bio-wax and nanocellulose coatings to enhance barrier properties, and additives that boost paper performance for food packaging applications. As more regions and countries enact regulations impacting both single-use plastic packaging and PFAS in food packaging, more diverse approaches to addressing PFAS in sustainable food packaging may emerge as more companies seek to fill this key gap.

Sona Dadhania, Senior Technology Analyst at IDTechEx