PFAS in Plastics: Uses, Risks, and Management
Langan Helps Institute Strategies and Solutions to Manage PFAS in Plastics
The plastics industry plays a major role in the generation of PFAS, which presents significant environmental and public health challenges. Renowned for their resistance and stability, PFAS are persistent in the environment; within the plastics sector, they serve as processing aids, performance-enhancing additives, and the structural basis for fluoropolymers—high-performance plastics known for their chemical resistance and thermal stability. Yet the presence of PFAS can also be an unintended consequence of certain plastics manufacturing processes.
In this article, we explore how PFAS are used in plastics, where they can be released throughout the plastics lifecycle, emerging PFAS-free alternatives, and strategies for managing PFAS-related environmental risks.
Key Takeaways
- PFAS can enter the plastics lifecycle through fluoropolymers, polymer processing aids, and as unintended byproducts of certain manufacturing processes.
- PFAS releases can occur throughout the plastics lifecycle, from manufacturing and processing to consumer use, recycling, and end-of-life management.
- Managing PFAS in plastics may require investigation and remediation, permitting, and waste disposal.
- PFAS-free alternatives are an emerging area of focus, as manufacturers evaluate solutions such as high-performance thermoplastics, fluorine-free coatings, and elastomers.
How Are PFAS Used in Plastics?
PFAS are intentionally used in the plastics industry as fluoropolymers and polymer processing aids (PPA) to support manufacturing. PFAS can also form unintentionally as byproducts of certain manufacturing processes.
Fluoropolymers
A subclass of PFAS, fluoropolymers include polytetrafluoroethylene (PTFE—better known as Teflon). Prized for their chemical resistance, thermal stability, low friction, and electrical insulation, these materials are used in consumer products (e.g., non-stick cookware, waterproof fabrics), electronics, medical devices, and automotive components. Historically, fluoropolymer production has frequently employed PFAS as processing aids or surfactants, significantly contributing to their emissions.
Polymer Processing Aids
Additionally, PFAS are used in PPA to facilitate the manipulation of thermoplastics and prevent issues such as melt fracture during extrusion, which in turn reduces defects and increases production speed. PPA are integral to the aerospace, automotive, and chemical processing industries, as well as blow molding, injection molding, and profile extrusion processes.
Unintended PFAS Formation
PFAS can also form unintentionally during certain plastics manufacturing and treatment processes. One example is during the surface fluorination of plastic containers, which creates a barrier that enhances solvent resistance and reduces permeation. These containers are widely used for agricultural chemicals packaging, petroleum storage and pipe transmission, automotive fuels, paint products, food, and household and industrial cleaners. However, the process can inadvertently create PFAS byproducts that can get incorporated into stored products.
How Can PFAS Be Released Throughout the Plastics Lifecycle?
The lifecycle of plastics and fluoropolymers involves multiple stages of potential PFAS release, from production to disposal:
– Manufacturing and Processing
Significant releases can occur during PFAS chemical production, fluoropolymer manufacturing, and their incorporation into other plastics. Industrial facilities can emit PFAS into the atmosphere, wastewater, and solid wastes, leading to contamination if improperly managed.
– Consumer Use Phase
PFAS can be released during normal use of plastic products, leaching from plastic materials into the products they come into contact with. PFAS may also enter food packaging through recycling, posing a challenge for achieving a clean circular economy. On a larger scale, unintended consequences can include septic system discharge and wastewater treatment plant discharge.
– End-of-Life Management
Managing PFAS-containing plastics at the end of their life presents additional challenges. Recycling can introduce PFAS into recycled materials and new products. Landfilling can lead to PFAS leaching into soil and groundwater, and incineration may result in incomplete destruction and harmful byproducts.
Managing PFAS Risks in the Plastics Industry
Managing PFAS risks in the plastics industry requires understanding where PFAS may be present, how they are generated, and where releases may occur throughout the plastics lifecycle. This can include reviewing raw materials, processing aids, manufacturing processes, and other PFAS sources within operations and supply chains.
As PFAS regulations evolve, environmental due diligence may also extend beyond individual properties to include supply chain reviews and product assembly processes. Understanding historical manufacturing operations and potential PFAS release pathways can help companies identify environmental liabilities and potential contamination sources, and develop appropriate management strategies.
Langan helps clients institute best practices, strategies, and practical solutions for navigating various types of PFAS in plastics, which present consequences and challenges for property due diligence, investigation and remediation, industrial and stormwater permitting, and fill management/waste disposal.
PFAS-Free Alternatives for Plastics
As stricter regulations on PFAS products are implemented, the demand is growing for PFAS-free replacement chemistries in plastics manufacturing and processing. Potential alternatives include high-performance thermoplastics, fluorine-free coatings, and elastomers.
These alternatives can help manufacturers reduce their reliance on PFAS and ensure compliance with future PFAS regulations. However, identifying an appropriate alternative may depend on the specific application and the required characteristics, such as chemical resistance, thermal stability, durability, and friction. Manufacturers should evaluate potential substitutes based on both performance needs and environmental considerations to avoid replacing PFAS with other dangerous materials.
Navigating the Future of PFAS in Plastics
The presence of PFAS in the plastics industry represents a potentially complex environmental and public health issue. Their use, management, and disposal involve multiple potential release pathways. PFAS experts can navigate these challenges by delivering comprehensive lifecycle assessments and evaluating appropriate management strategies to address risks and meet evolving regulations.
Langan’s PFAS teams help clients manage PFAS challenges. Contact Langan to learn how our team can develop PFAS strategies for your organization.
A Senior Project Manager and Hydrogeologist at Langan, Adam Goldberg brings leadership and technical expertise to environmental consulting and the AEC industry. He specializes in site remediation, brownfield redevelopment, property due diligence, PFAS investigation strategy and forensics, and applied technologies. Goldberg is an industry expert on ITRC’s 1,4-Dioxane and PFAS committees, a member of Langan Engineering’s Emerging Contaminants Practice Group, and a brownfields redevelopment leader for Urban Land Institute’s Philadelphia Young Leaders Group, Industrial Council Practice, and Advisory Board.
PFAS in Plastics FAQs
Do all plastics contain PFAS?
No, PFAS are not present in all plastics. They may be intentionally used in certain plastics as fluoropolymers or polymer processing aids. PFAS can also occur unintentionally as impurities, contaminants, or byproducts of certain manufacturing processes.
How can you tell if a plastic product contains PFAS?
Determining whether a plastic product contains PFAS may require reviewing material specifications, supplier documentation, and information about processing aids or manufacturing methods. Analytical testing can help identify certain PFAS, but because PFAS comprise thousands of chemicals, no single analytical method can identify every PFAS that may be present.
How are PFAS in plastics regulated?
PFAS in plastics are subject to both federal and state requirements that can vary depending on the specific PFAS, product, use, or manufacturing process. The Environmental Protection Agency regulates and tracks PFAS under programs such as the Toxic Substances Control Act (TSCA) and Toxics Release Inventory (TRI).
How can manufacturers identify PFAS within their supply chains?
Manufacturers can identify PFAS within their supply chains by identifying materials and processes where PFAS may be intentionally used or unintentionally introduced. Mapping suppliers, auditing bills of materials for high-risk components, and collecting full material disclosures can help trace PFAS sources through the supply chain. Where documentation is incomplete, a targeted sampling strategy and analytical testing may help address data gaps.
Are PFAS and microplastics the same thing?
No, PFAS and microplastics are different types of contaminants, and their identification, sources, and methods of investigation differ. PFAS are a broad class of fluorinated chemicals, while microplastics are small plastic particles. However, the two contaminants can overlap because some plastic materials, including microplastics, may contain or be associated with PFAS.