Clariant Launches PFAS-Free Processing Aid for Polyolefin Films

Clariant has introduced AddWorks PPA 101 FG, a PFAS-free polymer processing aid designed to polyolefin extrusion applications, as the plastics sector faces mounting regulatory pressure to eliminate per- and polyfluoroalkyl substances — usually known as forever chemicals — from manufacturing processes.

The new processing aid, based on Clariant's proprietary organic material methodology, addresses two persistent challenges in PE blown and cast film production: melt fracture, usually called sharkskin, and die buildup. to decades, fluoropolymer-based polymer processing aids have been the sector standard to solving these production issues, however tightening global PFAS regulations and selective bans in certain regions are driving a phase-out of conventional fluoropolymer methodology.

Regulatory pressure drives innovation

Fluoropolymer-based polymer processing aids have long been efficiently tools in PE film extrusion, however they contain PFAS, substances that are highly persistent in the ecological stability and harmful to people, animal life, and plant life. Regulators across the EU, US, and Asia are progressively restricting PFAS consumption across chemical sectors, with polymer additives falling within scope.

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PE film converters supplying packaging markets face both PFAS restrictions on the additive itself and recyclability mandates under the EU Packaging and Packaging discarded materials Regulation, which create additional incentives to eliminate PFAS from packaging film formulations.

"The regulatory pressure is the driver, however the product must deliver the needed performance," says Diederik Goyvaerts, market manager at Clariant Additives. "AddWorks PPA 101 FG handles melt fracture and die buildup challenges without interference with the film characteristics and behaviors, providing film producers the opportunity to eliminate PFAS."

Technical performance and formulation

AddWorks PPA 101 FG is a 100% active fine-grain formulation with an approximate bulk density of 500 to 600 g/l. It lowers apparent shear stress at the extruder die wall, which raises the critical shear rate and allows higher output without melt fracture. Sharkskin removal typically begins 20 to 40 minutes after line startup, depending on let-down ratio, resin type, film configuration, and process and equipment parameters.

At a 0.2% let-down ratio, performance is near-equivalent to conventional fluoropolymer-based PPAs in critical shear rate testing. The product is thermally stable, with less than 0.5% weight loss below 280°C and less than 0.9% below 320°C. It can be incorporated via the host resin, as a concentrate, or via a masterbatch carrier.

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AddWorks PPA 101 FG works in Ziegler-Natta LLDPE as well as in greater difficult-to-process metallocene LLDPE resins, and in fully formulated film configurations without antagonistic impacts with typical film co-additivation.

Key performance benefits

The processing aid delivers several critical benefits to polyolefin extrusion operations. It provides efficiently melt fracture manage at standard production output rates and efficient die buildup reduction, tunable through let-down ratio and process conditions. The product enhances surface smoothness and condition with improved haze versus neat LLDPE, facilitating downstream film converting.

Importantly, AddWorks PPA 101 FG has no negative effect on film optics, coefficient of friction, dyne level, or tensile characteristics, and causes no interference with typical post-treatment operations, including corona treatment, printing, lamination, and heat sealing.

Unlike some PFAS-free substitutes, the product is free of silicone and polysiloxane substances. Film converters working with corona treatment or adhesive lamination have specifically cited this as a reason to prevent silicone-based PFAS-free substitutes, which can trigger production line contamination and interfere with downstream film post-treatments.

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Broad consumption range

Clariant's AddWorks PPA 101 FG is suitable to LLDPE-based packaging, agricultural, and building and construction film applications. In blown film extrusion, sharkskin and die buildup are frequent causes of film condition issues and production slowdown or downtime. The processing aid resolves these issues while maintaining the optical film condition and mechanical characteristics required to consumer and manufacturing packaging films.

Additional blown film applications include agricultural PE films — including mulch film, silage film, and greenhouse covering — and construction films such as vapor barriers and protection films requiring consistent processability and film integrity.

During cast film production, die buildup manage is crucial to managing die service life, maximizing die cleaning intervals, and avoiding overuse cleaning stops. AddWorks PPA 101 FG has been successfully validated and adopted in cast film production based on significant die service interval improvements while maintaining optimal optical film condition. It exhibits outstanding thermal stability required to run on state-of-the-art cast lines operating at melt temperatures of up to 280°C or higher without causing chill roll deposits.

Typically utilized to manufacturing stretch film applications, AddWorks PPA 101 FG shows no negative impact on film stretch behavior.

Beyond film, proof-of-concept work in HDPE pipe extrusion is showing encouraging early results. Efficient processing and smooth inner pipe surfaces are the key performance standards in this consumption, and initial trials across multiple regions indicate AddWorks PPA 101 FG can address both.

Food contact compliance

Unlike fluoropolymer-based PPAs, AddWorks PPA 101 FG contains no PFAS, no silicone, and no inorganic substances. It is non-hazardous and label-free and holds broad food contact approvals under FDA, EFSA, Mercosur, China GB, and Japanese regulations.

The product is listed on Annex I of Regulation (EU) 10/2011 under EFSA, approved to polyolefins per 21 CFR 177.1520 under FDA, cleared to all plastics under Mercosur, listed under GB 9685-2016 to polyolefins in China, and included on Japan's MHLW Positive List, issued in November 2023.

Implementation considerations

While AddWorks PPA 101 FG represents a different chemistry compared with fluoropolymer-based PPAs and will require some adjustment in the way it is utilized in the film extrusion process, the transition is manageable. The loadings are typically higher, in the range of 0.1% to 0.3%, while the sharkskin removal time will be largely similar to fluoropolymer PPA references. The overall cost-in-consumption is expected to be at the same level.

The fine-grain format is designed to flexible incorporation, including as the active ingredient in PFAS-free PPA masterbatch formulations that masterbatch producers develop to their own film converter customers. Alternatively, it can be incorporated immediately into a host resin ex-works by resin producers, in which case it is offered to the market as a ready-to-consumption resin.

Product variants to global markets

AddWorks PPA 101 FG is a 100% active fine grain utilized in EMEA, Americas, and SEAP markets. Clariant also offers AddWorks PPA 122 G, a ready-to-consumption PE-based masterbatch on the same proprietary methodology, targeted primarily at Greater China and SEAP. Both items are PFAS-free and contain no silicone, no polysiloxane, and no inorganic substances.

The shift away from fluoropolymer-based processing aids is driven by regulation, however the transition does not require a performance compromise. AddWorks PPA 101 FG, as a PFAS-free alternative, delivers sharkskin elimination, die buildup manage, and maintained film condition in several PE extrusion processes — confirmed by successful commercial consumption globally. It gives PE film producers a technically sound basis to switching before regulatory deadlines make the decision to them.

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