Horizon Europe ZeroF Project: Development of verified, safe, and sustainable PFAS-free coatings for food packaging and upholstery textile applications

As the EU prepares to tighten regulations on per- and polyfluoroalkyl substances (PFAS) in 2026, the race is on for safer alternatives. ZeroF brings together 12 research and industry partners from nine countries, coordinated by Finland's leading research center VTT. Its goal is to develop safe and sustainable PFAS-free coatings for food packaging and upholstery textiles, while maintaining the beneficial properties of traditional coatings. "We need solutions that perform as well as PFAS, without the risks," says Miika Nikinmaa, Biomaterials Solutions Leader at VTT. "The industry needs to quickly adapt to upcoming regulations to ensure safety and performance are not compromised." Frameworks and Results ZeroF uses the Joint Research Centre's (JRC) Safe and Sustainable by Design (SSbD) framework method to develop materials, optimize formulations, and assess safety, performance, and sustainability. This approach ensures that the coatings developed are effective, environmentally friendly, safe, and compliant with regulatory standards. The project focused on creating hybrid organic-inorganic coatings for textiles and advanced barrier solutions for molded packaging. Researchers have improved the water resistance of PFAS-free textiles and are exploring innovative chemistry to enhance oil repellency.

So far, the team has made significant progress in developing PFAS-free coatings for textiles and packaging, including a product called ORMOCER®, and carbohydrate fatty acid ester-based coatings that demonstrate excellent water and oil resistance. ZeroF has eliminated harmful solvents, replaced hazardous catalysts, and optimized formulations with advanced additives and polymers to ensure robust performance and safety. Spray and powder coating techniques have been refined to support industrial-scale production. Life cycle assessments and consumer surveys offer insights into sustainability and market potential, supporting the real-world application of ZeroF’s innovations. Collaborative Efforts Replacing PFAS is not easy, and achieving strong water and grease repellency while keeping costs reasonable was a key challenge. ZeroF aims to reduce environmental impact by 25% and keep cost increases for consumers below 20%. Furthermore, gaps in safety data for PFAS alternatives and the limited applicability of existing assessment tools complicated the research process. "The lack of comprehensive safety data made it difficult to fully evaluate PFAS alternatives," Nikinmaa notes. "We needed a more robust database to guide development and establish regulatory compliance."

ZeroF's success so far is also due to its collaboration with other EU-funded initiatives, such as BIO-SUSHY, PROPLANET, and TORNADO. Participation in ECOSYSTEX also provides a valuable network for sharing knowledge, while close cooperation with SSbD networks, such as IRISS, maintains alignment with the principles of safety and sustainability by design at every stage of development. A Safer Future: Newly developed barrier coatings are on their way to commercial production, particularly in the molded packaging sector. In textiles, researchers are refining oil and chemical resistance to expand applications to areas such as protective clothing. To further raise awareness, a dedicated campaign will be launched in 2025 highlighting the benefits of PFAS-free solutions. "It's not just about regulations; we want consumers and businesses to understand why it's important to switch to safer alternatives," adds Nikinmaa. This will culminate in a final event in October 2025, where the project's findings will be showcased and pave the way for wider adoption. When the project concludes in December 2025, the final phase will explore biodegradability for packaging applications and sustainable end-of-life solutions for textiles to prevent long-term environmental damage. This ensures that safer alternatives are accessible and practical for widespread adoption.