Since August 12: No PFAS in food packaging film and plastics production – is it possible?

High-performance PVD coatings help manufacturers move toward more sustainable food packaging film and plastics production.

Additives such as PFAS improve melt flow, stabilize plastics processing and help ensure consistent product quality. Due to environmental and health concerns, however, manufacturers increasingly need to modify their formulations. PFAS-free PVD coatings from Oerlikon Balzers support the efficient processing of modified formulations and comply with the new EU requirements.

PFAS (per- and polyfluoroalkyl substances) are highly stable fluorinated chemicals used as processing aids in plastic melts or as release agents. They reduce friction between the polymer melt and metal surfaces and help prevent processing defects such as melt fracture, sharkskin effects, nozzle build-up and drooling. In addition, they reduce adhesion and improve the surface quality of the final product.

Their high stability, however, is also what makes PFAS problematic. They persist in the environment, contaminate soil and water, and accumulate in the human body. PFAS-containing additives are particularly critical in food-contact applications because they may migrate into packaged food. Since August 12, 2026, specific PFAS limits under the EU Packaging and Packaging Waste Regulation (PPWR, Regulation (EU) 2025/40) apply to food-contact packaging.

Modified formulations can create processing challenges
To comply with these requirements, plastics manufacturers need to modify their formulations using alternative or additional processing aids to maintain flow behavior and release properties. However, these alternatives do not always deliver the same performance as PFAS. As a result, the interaction between polymer formulation, process conditions and tool surface becomes increasingly important.

Michael Bilo, Key Account Manager Plastics at Oerlikon Balzers, describes the challenge: “We have customers producing multi-layer PE/HDPE barrier films for food packaging. Each layer measures only a few micrometers (µm). Without PFAS, these materials can no longer be processed as reliably at such low thicknesses. Film stability decreases, tears occur more frequently, and nozzle build-up as well as drooling occur significantly more often.”

Such issues are not limited to PFAS replacement. New additives, bio-based polymers and recycled materials can create similar challenges.

“Customers often come to us when a new formulation causes processing problems. We analyze tool geometry, substrate material, surface condition and the specific defect pattern within the context of the production process and the polymer being used,” says Michael Bilo.

PVD coatings: Less adhesion, less wear
PVD coatings for melt-contact surfaces support the process where PFAS-containing additives previously delivered important functionality. They improve sliding and flow behavior, reduce adhesion and deposit formation, and protect against corrosion.

With BALINIT CROMA PLUS and BALINIT MOLDENA, Oerlikon Balzers offers PFAS-free, REACH-compliant solutions for extrusion, injection molding and die casting that support compliance with the requirements of the EU Packaging and Packaging Waste Regulation.

Both coatings are exceptionally hard and highly resistant to wear, corrosion and oxidation. They reduce adhesion and deposit formation on tool surfaces, extending the service life of screws, barrels, dies, nozzles and mold inserts. BALINIT MOLDENA is particularly suitable for abrasive materials such as glass-fiber-reinforced plastics, plastics with high flame-retardant content and recycled materials.

Longer tool life, lower costs
Coated tools achieve longer service life, reduce maintenance and tooling costs, and minimize unplanned downtime. In tests with BALINIT MOLDENA, more than 200,000 injection cycles were achieved while maintaining consistent part quality, compared with approximately 40,000 cycles using a standard coating. More stable processes, reduced adhesion and improved surface quality simultaneously increase production efficiency and lower part costs.

Wear-reducing PVD coatings that minimize adhesion on tool surfaces help mitigate the effects of modified formulations. They stabilize material flow, extend cleaning intervals and reduce downtime. At the same time, these coatings contribute to sustainability by extending tool life and supporting the reliable processing of new and recycled plastics.

This enables the plastics industry to maintain efficient production and consistent quality while meeting regulatory requirements as well as the expectations of customers and consumers.

About Oerlikon Balzers
Oerlikon Balzers is one of the world’s leading suppliers of surface technologies that significantly improve the performance and durability of precision components as well as tools for the metal and plastics processing industries. 

Extremely thin and exceptionally hard coatings, marketed under the BALINIT and BALIQ brand names, reduce friction and wear. The BALDIA portfolio of diamond coatings enables top performance even when machining very challenging materials. The BALITHERM brand opens up a broad range of heat treatment services, whereas BALTONE comprises coatings that are available in a full range of elegant colours, perfectly suited for decorative applications. BALORA gives components effective protection from oxidation and corrosion in environments with extremely high temperatures. BALIMED ThinFilm coatings, with wear-resistant, biocompatible, antimicrobial and chemically inert properties, have been developed especially for medical applications. Under the BALIFOR technology brand the company has introduced technologies which provide tailor-made solutions for the automotive market.

Worldwide, more than 1,300 coating systems are in operation at Oerlikon Balzers’ facilities and its customers. Equipment engineering and assembly of Balzers’ systems are processed in Liechtenstein and in Bergisch Gladbach (Germany). Oerlikon Balzers operates a network of more than 100 coating centers in 35 countries in Europe, the Americas and Asia. Oerlikon Balzers is – together with Oerlikon Metco, Oerlikon AM, Oerlikon HRSflow, Oerlikon Riri and Oerlikon Fineparts – part of the Switzerland-based Oerlikon Group.

About Oerlikon 
Oerlikon is a global leader in material science engineering. Through the right combination of surface technologies, advanced materials, coating equipment, engineered components and advanced manufacturing, we help customers improve the performance, efficiency, durability and sustainability of their products and processes. Our technologies are often invisible to the end user, but mission-critical to the industries that power modern life: aerospace, energy, semiconductors, medical, luxury, tooling, automotive and general industries. 
Headquartered in Pfaeffikon, Switzerland, Oerlikon operates in 38 countries with a global workforce of around 10,000 people. In 2025, Oerlikon achieved sales of CHF 1.6 billion.