In a breakthrough poised to transform sustainable food packaging, researchers at Northwestern University have developed a novel, PFAS-free coating using graphene oxide—offering a safer and eco-friendly alternative to conventional grease-resistant materials. The innovation emerges as the packaging industry faces mounting regulatory and consumer pressure to eliminate toxic per- and polyfluoroalkyl substances (PFAS).

A safer barrier without compromise

PFAS compounds, often dubbed “forever chemicals,” have long been used in food packaging to provide water and oil resistance. However, due to their persistence in the environment and links to serious health risks—including cancer, endocrine disruption, and liver damage—regulatory bans are rapidly spreading worldwide.

Northwestern University’s new coating leverages graphene oxide, a carbon-based nanomaterial known for its impermeability and strength. The coating forms an ultra-thin, high-performance barrier that resists grease and moisture without the need for fluorinated chemicals. Most importantly, it can be applied to paper-based packaging using scalable, water-based processes like spraying or dipping.

Designed for compostable packaging

What sets this technology apart is its compatibility with compostable and recyclable materials. Unlike PFAS coatings, which hinder biodegradability and contaminate recycling streams, the graphene oxide solution is designed to be safe for both human health and end-of-life packaging recovery systems.

“We created a functional barrier that meets industry needs without relying on persistent pollutants,” said Jiaxing Huang, lead researcher and professor of materials science and engineering at Northwestern. “Our coating is transparent, non-toxic, and effective—even with a minimal amount of material.”

“The idea is to remove PFAS from food packaging without losing performance, and we believe this is a viable industrial alternative,” added Huang.

Implications for packaging converters

For converters and food packaging producers, this new material could become a key asset in reformulating products to meet stricter safety and sustainability criteria. Large brands, especially in the quick-service restaurant and ready-to-eat sectors, are actively seeking PFAS-free solutions as deadlines loom for compliance with new legislation across the U.S. and EU.

Unlike many experimental coatings, this solution is positioned for rapid commercialization. The research team emphasizes its scalability, affordability, and adaptability to various substrates—a critical factor for mass-market adoption.

Strategic advantages and future potential

Beyond regulatory alignment, the use of graphene oxide coatings presents opportunities for differentiation in a crowded market. Brands that adopt such materials early may benefit from enhanced consumer trust, improved ESG ratings, and packaging that aligns with circular economy goals.

Northwestern’s innovation could also serve as a platform for further functional enhancements—such as antimicrobial properties or oxygen barriers—paving the way for smart, multifunctional food packaging.

As the packaging world transitions away from legacy chemicals, solutions like this one exemplify how science and design can converge to create high-performance, human-safe, and environmentally responsible packaging materials. For designers, brands, and manufacturers alike, the era of PFAS-free packaging has officially entered a new phase—one built on innovation at the nanoscale.