ZeroF has advanced the development of PFAS free material solutions through two main chemistries: cellulose based fatty acid esters for packaging applications and silane based organic–inorganic hybrids for textile use. Across the project, workflows in both packaging and textile development followed a shared, structured approach, moving from chemical synthesis and design to formulation, coating application, performance testing, and prototype validation.
Significant progress was achieved in synthesizing biobased and organic–inorganic complexes, as well as developing various biobased waxes. A key outcome is a biobased coating system based on polysaccharide fatty acid esters, optimized through variations in polysaccharides, fatty acid chains, and substitution degrees. For textile applications, water based hybrid coatings have been formulated to increase hydrophobic and oleophobic performance while meeting end use requirements. Laboratory scale results already showed contact angles comparable to PFAS based systems, and larger scale application tests validated it. Oil repellence was evaluated by using typical oils used in daily life to ensure that the developed technology has a viable performance in the selected application.
On the packaging side, several batches of the optimized coating system were produced and shared between partners enabling different tests. New powder coating and dry coating processes were established, yielding promising results for water vapor barrier properties and Cobb performance, as well as enhanced oil barrier and KIT values. Parallel studies on biowaxes in wet processes clarified their role in both coatings and wet end additions.
Throughout the project, collaboration among partners has been essential, ensuring efficient sharing of materials, coating batches, and data. The consortium also initiated full implementation cycle of the Safe and Sustainable by Design (SSbD) framework. This included environmental impact assessment via LCA, Life Cycle Costing, and Environmental Footprint methods, alongside toxicological evaluation grounded in regulatory mapping and Green Toxicology principles.
Computational modelling supported predictions of toxicological behaviour and performance, reducing the need for in vitro testing and supporting future certification and regulatory preparedness. All safety, sustainability, and performance data are integrated into the eNanoMapper FAIR database to ensure long term accessibility and reusability. In addition, the project developed SSbD models aligned with the European Commission’s recommended framework, ensuring adaptability to sectors beyond packaging and textiles.
Pilot scale activities included trials with 3D packaging, 3D textiles, and roll to roll upholstery fabrics. Continuous SSbD assessment, stakeholder engagement, certification planning, and dissemination activities have contributed to the project’s broader policy relevance, supporting the Green Deal, Chemicals Strategy for Sustainability, Zero Pollution, and the Circular Economy objectives.
