A new coating targets PFAS in packaging

A bio-based coating developed as an alternative to PFAS is moving closer to commercial scale, offering packaging manufacturers a potential way to achieve water and stain resistance without using so-called “forever chemicals”. Developed by London-based Demeter Bio, the technology is designed to reproduce some of the functional properties that have made PFAS widely used in packaging and other applications.

The coating, known as Fibrepel, uses biomaterials and has been developed for applications including packaging, textiles, upholstery and hygiene products. Its development comes as regulatory restrictions on PFAS continue to expand across Europe, increasing pressure on manufacturers to identify alternatives that can deliver comparable performance.

Replacing performance without introducing new concerns

PFAS have traditionally been used where packaging requires resistance to water, grease and stains. However, concerns surrounding their persistence in the environment and potential health effects have led governments and industry to seek alternatives.

Some PFAS-free coatings have relied on microplastics or other synthetic materials to provide barrier performance. According to Demeter Bio, these solutions can introduce additional environmental concerns while failing to provide the same resistance to substances such as oils and alcohols. The company has therefore focused on developing a coating based on biomaterials that can address several of these limitations simultaneously.

Recognition supports commercial development

The Fibrepel technology recently won the Environment category at the Royal Society of Chemistry's Emerging Technologies Competition. The recognition highlights the growing interest in materials capable of replacing persistent chemicals while maintaining the technical properties required by industrial applications.

For packaging manufacturers, the development is particularly relevant as PFAS restrictions increase the need for alternatives in food-contact and fibre-based packaging. A coating capable of providing effective surface protection could help manufacturers maintain functionality while adapting to changing regulatory requirements.

Performance remains critical for packaging

Replacing PFAS is not simply a question of removing fluorinated chemistry from packaging. Alternative coatings must provide sufficient resistance to moisture, grease and other substances while remaining compatible with packaging substrates and existing manufacturing processes.

This performance requirement is especially important for paper and fibre-based packaging, where coatings are often necessary to provide the barrier properties required for food and beverage applications. The success of alternatives will therefore depend on their ability to combine regulatory compliance with reliable packaging performance.

Scaling alternative coatings

Demeter Bio describes Fibrepel as a scalable technology capable of being adapted for different products and industries. Moving from development towards larger-scale production will nevertheless require continued validation of performance, manufacturing compatibility and commercial economics.

Scale will also be important for making alternative coatings competitive with established materials. As more companies face restrictions on PFAS, demand for suitable replacement technologies is expected to increase, potentially accelerating investment in new barrier coating solutions.

The search for PFAS alternatives is accelerating

The development of Fibrepel reflects a broader transformation in packaging materials as manufacturers move away from persistent chemicals and investigate bio-based alternatives. Other recent innovations have also targeted PFAS-free barrier coatings for paper and fibre packaging, indicating that the market is rapidly expanding. :contentReference[oaicite:1]{index=1}

For the packaging industry, the challenge will be to ensure that the next generation of coatings does not simply replace one environmental problem with another. Solutions that combine effective barrier performance, suitable end-of-life characteristics and scalable production could play an increasingly important role as PFAS regulations become stricter across global markets.