Periodic Reporting for period 2 - ZeroF (Development of verified safe and sustainable PFAS-free coatings for food packaging and upholstery textile applications)
Okres sprawozdawczy: 2024-07-01 do 2025-12-31
The ZeroF project contributed to the replacement of PFAS in food packaging and upholstery textiles by developing safer, high performance PFAS free coating systems. The overarching goal was to create verified PFAS free coating technologies and demonstrate their feasibility through laboratory, semi pilot, and pilot scale implementation. This included hybrid coatings for textiles, polysaccharide based coatings for packaging, and processing methods suitable for industrial adoption.
PFAS substances are being replaced with two alternative chemistries: cellulose based fatty acid esters for packaging applications and silane based organic–inorganic hybrids for textile use. The project was structured into three main work streams: food packaging, upholstery textiles, and SSbD (Safe and Sustainable by Design) analysis.
Both the packaging and textile workflows followed a comparable development path, progressing through chemical design, formulation, coating application, and performance validation. The SSbD work stream enabled active assessment of human health, environmental and socio-economic impacts using well established and standardized methodologies, such as Life Cycle Assessment, Life Cycle Costing, Environmental Footprint, and in vitro toxicity testing based on OECD test guidelines.
Computational tools were used to model the toxicology and performance of the new chemistries in silico, reducing the need for in vitro testing and supporting future certification and standardization efforts. A certification and regulatory roadmap was established to highlight future requirements and remaining knowledge gaps.
PFAS substances are being replaced with two alternative chemistries: cellulose based fatty acid esters for packaging applications and silane based organic–inorganic hybrids for textile use. The project was structured into three main work streams: food packaging, upholstery textiles, and SSbD (Safe and Sustainable by Design) analysis.
Both the packaging and textile workflows followed a comparable development path, progressing through chemical design, formulation, coating application, and performance validation. The SSbD work stream enabled active assessment of human health, environmental and socio-economic impacts using well established and standardized methodologies, such as Life Cycle Assessment, Life Cycle Costing, Environmental Footprint, and in vitro toxicity testing based on OECD test guidelines.
Computational tools were used to model the toxicology and performance of the new chemistries in silico, reducing the need for in vitro testing and supporting future certification and standardization efforts. A certification and regulatory roadmap was established to highlight future requirements and remaining knowledge gaps.
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.
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.
ZeroF demonstrated that PFAS free coatings can match or approach PFAS level performance, providing strong evidence that sustainable alternatives are technically feasible. Packaging prototypes achieved high water and oil barrier performance, approaching or exceeding defined project KPIs. Textile coating systems reached high water repellency and abrasion resistance, with progress toward improved oil repellency. SSbD guided formulation and process choices showed which design parameters most influence performance with sustainability trade offs. The project produced high quality, interoperable datasets enabling advanced modelling, uncertainty quantification, and data driven material design.
These achievements push forward both the scientific development of PFAS free chemistries and the practical understanding of how to design safer, more sustainable coating materials.
These achievements push forward both the scientific development of PFAS free chemistries and the practical understanding of how to design safer, more sustainable coating materials.