Through extensive research and collaboration, ZeroF aims to identify and implement effective strategies that not only mitigate the environmental impact of PFAS pollution but also protect public health through innovative PFAS-free coatings.
PFAS, or per- and polyfluoroalkyl substances, are a family of several thousand chemicals that are widely used in everyday products such as waterproof clothing, nonstick cookware, food packaging, cosmetics and even medical equipment. Discovered in the 1930s, PFAS have been incorporated into consumer and industrial products since the 1950s, valued for their ability to resist heat, oil, stains and water.
As a result, these chemicals have become essential in many industries. However, growing concerns have emerged regarding their potential health and environmental effects. PFAS are persistent chemicals that do not naturally degrade, accumulating over time in both the environment and the human body. Some PFAS compounds have been linked to long-term health risks, including cancer, liver damage, hormone disruption, and weakened immune function.
A recent Eurobarometer survey by the European Commission highlights a significant gap in public awareness about PFAS. Only 29% of Europeans are familiar with these substances, often referred to as ‘forever chemicals’ due to their persistence. However, once informed, 81% of respondents expressed concerns about the potential health risks, and 84% were worried about their environmental impact.
The ZeroF project
Tackling these challenges, the ZeroF project was launched in 2023, bringing together 12 European partners from research and industry. Funded by the European Commission and the Swiss State Secretariat for Education, Research, and Innovation under the Horizon Europe programme, the project aims to develop safe, sustainable alternatives to PFAS. The mission is to replace PFAS in textiles and food packaging with high-performance, PFAS-free coatings that are safe for human health and the environment.
As Miika Nikinmaa, project coordinator at VTT, explains: “In the ZeroF project, we have developed PFAS-free coatings for textiles and packaging, achieving excellent water and oil barrier properties. The performance of these novel materials has improved with each generation, and the results are very promising.
“Additionally, we have evaluated relevant standards and regulations to identify areas where activities are needed to facilitate the adoption of emerging PFAS-free materials. The challenge of eliminating PFAS waste is extensive and complex, but we are fortunate to work on this important topic and are committed to continuing our efforts.”
With much of the European public still unaware of the risks posed by PFAS, the ZeroF project is launching an awareness campaign in 2025 to inform the public and industry and support ongoing research efforts and political discussions at the EU level. The goal is to explain the dangers of PFAS as part of the broader chemical crisis and, most importantly, to promote sustainable solutions, particularly ZeroF’s work in developing safer materials that benefit both the environment and future generations.
The campaign will address key concerns about performance, safety, sustainability, and cost. It emphasises that the objective is not to replace PFAS with another harmful substance but to develop truly sustainable alternatives, such as those created by ZeroF, that reduce environmental impact and pose no harm to human health. Everyone is encouraged to follow the campaign on ZeroF’s communication channels and explore these important topics in greater depth once it is launched.
Breaking barriers: Ensuring performance with PFAS-free coatings
A major concern when replacing PFAS has always been whether alternative materials can deliver the same protective properties, such as water and oil resistance, as the multipurpose chemicals they replace. After years of research into PFAS alternatives, the answer is clear: PFAS-free materials with comparable performance do exist.
ZeroF has developed ORMOCER® coating systems for textiles that deliver excellent water resistance, an essential property for upholstery, such as the couches in our living rooms. Ongoing research is focused on improving oil repellence by incorporating additives like silica particles and copolymers, ensuring that the fabric retains its softness and durability while achieving superior barrier performance.
In food packaging, ZeroF has made significant progress with coatings that incorporate cellulose fatty acid esters (CFAEs). These coatings show superior hydrophobic properties compared to traditional PFAS-based materials, offering excellent oil and water resistance. This is crucial for items like pizza boxes and food containers, where preventing contamination and maintaining food safety are essential. Additionally, biowax emulsions have been developed to enhance water resistance and vapour transmission, further improving the performance of these materials.
Our results demonstrate that PFAS-free coatings can not only match but even exceed the performance of traditional PFAS-based alternatives, offering exciting new possibilities for industries that have relied on these harmful chemicals for years.
Safety first: Reducing health risks with the safe and sustainable-by-design approach
As we learn more about the dangers of PFAS, studies have shown how these chemicals are present in both the environment and our bodies. A recent government-funded study published in Environmental Health Perspectives by a team of UCSF researchers found PFAS in the blood of 302 pregnant women and their babies, with 97% of the samples containing PFOS, a type of PFAS associated with serious health issues, including birth defects. Despite efforts to reduce PFOS use, these chemicals persist in our bodies, highlighting the urgent need for safer alternatives.
To address this, ZeroF’s coatings are developed with a strong emphasis on safety, guided by the Safe and Sustainable-by-Design (SSbD) framework. This framework ensures that the chemicals used in our research are carefully evaluated for safety at every stage. Safety experts use toxicity prediction tools and conduct rigorous safety assessments to check new chemicals developed by our research teams, ensuring that they do not pose risks to human health or the environment. This approach guarantees that harmful substances are avoided and only safe, sustainable alternatives are pursued.
By focusing on sustainability and safety from the outset, ZeroF is setting a new standard in product design. The shift to PFAS-free products helps mitigate the risks associated with long-term exposure to these chemicals, offering a safer option for human health and the environment.
Sustainable coatings: Reducing environmental footprint through lifecycle assessments
PFAS have a significant impact on the environment, as they do not break down naturally, leading to their accumulation in ecosystems worldwide. In 2023, the Forever Pollution Project, a cross-border and interdisciplinary collaboration of European journalists, revealed the extent of PFAS contamination across Europe for the first time, highlighting the widespread nature of this issue. Once released, PFAS contaminate water, soil, and wildlife, creating a persistent problem that is costly and challenging to address.
ZeroF is committed to developing coatings that not only eliminate harmful substances but also aim to reduce their environmental impact throughout their lifecycle. Through extensive life cycle assessments (LCAs), (LCAs), the ZeroF team evaluates the environmental impact of each of the developed coating formulations to ensure that the most sustainable components are selected. For example, LCAs have been conducted on the production of CFAEs. This process has helped identify materials with significant environmental impacts and led to improvements in the manufacturing process to reduce these impacts.
Additionally, ZeroF’s PFAS-free solutions align with European sustainability initiatives, such as the Green Deal and Circular Economy Action Plan, which focus on reducing hazardous chemicals and promoting sustainable industrial practices. By incorporating these principles, ZeroF aims to contribute to cleaner production methods and support environmental sustainability.
Affordability alternatives: Cost-effective solutions for industry and consumers
A common concern about switching to PFAS-free alternatives is the potential higher cost. However, ZeroF’s research shows that these coatings can be cost-effective in both production and long-term performance. Life Cycle Cost (LCC) analysis is used to evaluate the price of each coating formulation, along with its safety and sustainability. This ensures that the solutions are competitively priced while delivering long-term savings by reducing environmental cleanup costs and health-related issues caused by PFAS exposure.
Additionally, as our technologies scale, production costs will likely decrease, making PFAS-free coatings more accessible to a broader range of industries. By eliminating the use of expensive, harmful materials, ZeroF’s coatings provide a more cost-effective and sustainable solution for manufacturers, helping them to meet industry standards while promoting a safer and more environmentally friendly approach to their production.
Conclusion: A future without PFAS
ZeroF’s development of PFAS-free coatings for textiles and food packaging represents a significant step forward in creating safe and sustainable alternatives for industries and consumers. These innovative PFAS-free coatings offer performance that matches or exceeds that of traditional PFAS-based products while addressing critical health and environmental concerns. By prioritising safety assessments, reducing environmental footprints, and ensuring economic viability, ZeroF is working on solutions that aim to eliminate bioaccumulation, reduce health risks, and help protect future generations from harmful chemicals.
Beyond the research, the success of PFAS-free coatings also depends on raising public awareness and fostering legal and political support. Readers are encouraged to share this article, return for updates on the upcoming awareness campaign through ZeroF channels, and engage in discussions about projects like ZeroF and others that are paving the way toward a PFAS-free future. By broadening acceptance of these new solutions and advocating for stronger legislation, the transition to safer, more sustainable alternatives can be collectively driven.
Contact information and further resources
For more information on the ZeroF project, visit our website or follow us on social media. Stay informed about the latest research, upcoming events, and the launch of our awareness campaign.
Please note, this article will also appear in the 21st edition of our quarterly publication.
