1. Introduction
Increasing regulatory scrutiny and corporate sustainability objectives are driving many manufacturers to evaluate alternatives to per- and polyfluoroalkyl substances (PFAS) for their polymer processing operations. Fluoropolymer-based processing aids have long been valued for improving extrusion efficiency and surface quality, but the landscape is shifting rapidly as restrictions on PFAS expand across regions and end markets.
This PFAS transition guide is developed to help converters understand why the change is happening, what challenges to expect during conversion, and how to build a structured plan for adopting non-fluorinated processing aids without compromising manufacturing performance or product quality.
Key Takeaways
- Why companies are considering PFAS alternatives
- Common processing challenges during conversion
- Steps for a successful transition
- How alternative technologies can support manufacturing performance
2. Understanding PFAS Processing Aids
What Are Processing Aids?
Polymer processing aids are additives used primarily in polyolefins and extrusion applications to reduce melt fracture and improve surface quality, therefore, reducing die buildup. They help the polymer melt flow more smoothly through the die, lowering processing pressure and enhancing throughput. Typically used at low loading levels, these additives act at the polymer–metal interface to promote clean, stable extrusion and consistent product appearance.
Why PFAS-Based Additives Became Popular
Fluoropolymer-based processing aids earned broad adoption because they delivered reliable performance across a wide range of resins and processing conditions:
- Processing efficiency and die lubrication that reduce extrusion pressure
- Surface quality improvement that eliminates melt fracture and sharkskin
- Equipment throughput benefits that support higher output rates
Why Manufacturers Are Evaluating Alternatives
Despite their performance advantages, PFAS-based additives are facing growing pressure from multiple directions, prompting manufacturers to pursue fluoropolymer processing aid replacement:
- Regulatory developments restricting PFAS use across regions and applications
- State-specific positions around PFAS (MN, ME, etc.)
- Customer requirements for safe chemistries and transparent material disclosures
- Corporate sustainability initiatives and ESG commitments
- Supply chain risk and continuity considerations as PFAS availability tightens
- Discontinuation of PFAS raw materials
- Business continuity risk
- Proactive risk management and future-proofing
3. Common Applications Affected by the Transition
The shift toward PFAS-free processing aids touches a broad range of extrusion processes:
- Film and sheet extrusion: blown film, cast film, stretch film
- Pipe and tubing: pressure pipe, irrigation pipe, industrial tubing
- Wire and cable: communication cable, power cable
- Other extrusion: profile extrusion, compounding operations
4. Challenges During PFAS Conversion
Removing fluoropolymer processing aids can reintroduce issues they were originally solving. Knowing what to expect is the first step in polyolefin extrusion optimization and helps teams avoid costly downtime during the switch.
- Melt fracture and sharkskin: surface defects caused by irregular melt flow at the die, visible as a rough or ribbed finish. These are often the first signs that a new additive package needs adjustment.
- Die buildup: additive or resin deposits at the die exit that shorten maintenance cycles and reduce line productivity. Effective die buildup control means that customers can run longer without shutting down their machines.
- Surface appearance changes: gels, streaking, and roughness that can affect product aesthetics and quality acceptance, particularly in visible film and sheet applications.
- Throughput reduction: possible output changes that require process optimization to recover, as higher melt viscosity without the processing aid can slow line speeds.
- Cleaning and conversion time: residual fluoropolymer must be removed and equipment properly prepared before introducing a new additive package, or cross-contamination can mask trial results.
5. Assessing Readiness for Transition
Before starting, ask whether your process, product, and operations are prepared. A clear picture of your current state prevents surprises and keeps trials focused.
- Process: resin types, output rates, die geometry, existing additive package
- Product: surface quality specifications, mechanical performance requirements, regulatory requirements
- Operations: planned trial schedule, available technical resources, production flexibility
Documenting these answers up front gives your team a benchmark to measure against and helps suppliers recommend the most appropriate PFAS-free processing aids for your specific application.
6. Building a Transition Plan
A structured approach minimizes risk. Follow the PFAS Transition Roadmap:
- Assess: establish baseline performance measure throughput, pressure, scrap rates, surface quality, and die buildup frequency.
- Benchmark: define success criteria: equivalent output rate, comparable product appearance, reduced maintenance requirements.
- Trial: conduct controlled trials: use single-variable testing, consistent operating conditions, and clear data collection methods.
- Optimize: monitor and optimize to adjust processing conditions, additive loading levels, and equipment settings based on trial data.
- Validate: confirm long-term performance and quality under production conditions over extended run lengths and gather operator feedback to document final operating parameters.
7. Alternative Technologies to Consider
Non-fluorinated processing aids offer a path forward. When evaluating options, consider their mechanism of action, typical applications, and performance characteristics.
Key Evaluation Criteria
- Processing performance: melt fracture reduction, die cleanliness (die buildup reduction), throughput, time to clear
- Sustainability considerations: regulatory alignment and corporate environmental goals, alignment with customer/brand owner specifications
- Operational impact: ease of implementation, trial duration, line changeover requirements
Effective extrusion processing aids should deliver comparable melt fracture reduction and die buildup control while aligning with your sustainability targets.
8. Best Practices for a Successful Conversion
- Prior to conversion: review formulation changes, communicate with suppliers, and prepare validation protocols.
- During conversion: record process data, inspect product quality frequently, and monitor equipment performance.
- After conversion: validate long-term performance, assess maintenance intervals, and gather operator feedback.
9. How Avient Can Help
Avient supports polymer processors at every stage of the transition with technical expertise and alternative technologies.
- Technical support services: material selection guidance, trial planning assistance, and process optimization support.
- Solution development: alternative processing aid technologies, formulation support, and application-specific recommendations.
- Validation assistance: performance testing, scale-up support, and commercial implementation guidance.
Ready to start your PFAS transition?
Connect with Avient's technical team to evaluate Cesa™ and Hiformer™ non-fluorinated processing aids tailored to your process and product requirements.
