PFAS and BPA Regulations: A Turning Point for Food Packaging Coatings

In recent years, regulatory authorities have proposed restrictions and bans on polyfluoroalkyl substances (PFAS) and bisphenol A (BPA) in food packaging materials. Notably, the European Union introduced regulations in 2024–2025 targeting these chemicals, while the Food Safety and Standards Authority of India (FSSAI) has also proposed restrictions on their use in food-contact materials. These developments are driving a major shift in the paints and coatings industry.

The regulations are primarily motivated by growing health and environmental concerns related to these chemicals, which are widely used in food-contact materials. Historically, PFAS and BPA have been used in packaging coatings because of their strong performance advantages, including grease resistance, durability, and chemical stability. However, increasing evidence regarding their environmental persistence and potential health risks has prompted regulatory restrictions and industry-wide reformulation efforts.

Understanding PFAS and BPA in Food Packaging

PFAS: “Forever Chemicals”

PFAS are a class of fluorinated compounds widely used in paper and cardboard packaging to provide oil- and water-resistant properties. They are commonly found in fast-food wrappers, microwave popcorn bags, pizza boxes, and grease-resistant papers.

However, PFAS are often referred to as “forever chemicals” because their strong carbon–fluorine bonds make them extremely persistent in the environment. These compounds can accumulate in soil, water, and the human body, raising concerns about long-term health effects such as immune system suppression, thyroid disorders, and certain cancers.

BPA in Packaging Coatings

BPA is widely used in the production of polycarbonate plastics and epoxy resin coatings, particularly for the internal lining of metal cans and beverage containers. These coatings protect packaging from corrosion and extend shelf life. Despite these benefits, BPA has been linked to hormonal disruption and reproductive health issues. Regulatory agencies have increasingly restricted its use in food-contact materials due to concerns that it may migrate from packaging into food.

Implications for the Paints and Coatings Industry

1. Elimination of BPA in Can Coatings: The EU has adopted a complete ban on the use of BPA in food contact material, including coatings, varnishes, and inks, with regulation coming into effect from January 2025 and a phase-out occurring through 2029. This has enabled a complete shift from epoxy lining in metal cans to safer alternatives.

2. Removal of PFAS from Functional Coatings: PFAS, valued for their water- and grease-resistant properties, are increasingly being phased out from paper and paperboard packaging coatings. As a result, the industry is shifting toward alternative, non-fluorinated barrier technologies.

   
   

   This transition may include the adoption of:

   • BPA-free epoxy systems

   • Polyester-based coatings

   • Acrylic or oleoresin-based coatings

   • Waterborne barrier coatings

3. Growth of Sustainable and Bio-Based Coatings: The push to eliminate PFAS and BPA is accelerating innovation in bio-based and sustainable coatings. These solutions are particularly relevant for paper-based packaging used in quick-service restaurants and takeaway food products.

   
   

   Potential alternatives include:

   • Plant-derived polymer coatings

   • PFAS-free grease barrier coatings

   • Biodegradable and compostable coating technologies

4. Material Shift: The market is rapidly moving toward water-based acrylic dispersions, plant-based polymers, and nano-clay reinforced coatings to achieve oil and grease resistance without "forever chemicals". 

PFAS and BPA-Free Solutions:

Several leading coatings manufacturers have introduced PFAS-free and BPA-free solutions for packaging applications, reflecting the industry’s increasing focus on safer and more sustainable materials.

PPG Industries launched PPG Hoba Pro 2848, expanding its HOBA internal coatings line with a non-bisphenol A solution designed for aluminium bottles used for water, wine, and other beverages. The company also expanded its aluminium beverage can easy-open end coatings portfolio with three BPA-NI solutions: PPG INNOVEL® PRO 2489, PPG INNOVEL® EVO 6720, and PPG iSENSE® 5018.

AkzoNobel Packaging Coatings introduced Accelshield™ 300 in late 2024, an internal coating for beverage cans formulated to be bisphenol non-intent (BPA-NI) and styrene-free while delivering enhanced corrosion protection.

Solenis LLC continues to expand its portfolio of TopScreen water-based, PFAS-free barrier coatings for paper and paperboard packaging, which are widely used in food service applications.

Most recently, BASF has also introduced a portfolio of polyphenylsulfone (PPSU) grades free from Bisphenol S (BPS) and Bisphenol A (BPA). The Ultrason® P range complies with EU Commission Regulation 2024/3190, which restricts the use of bisphenols in food-contact materials.

Toyo Printing Inks showcased its innovative solutions for the metal packaging industry to international stakeholders at the World Can Experience event.

Regulatory Trends

India: The Food Safety and Standards Authority of India (FSSAI) has proposed a comprehensive ban on PFAS and BPA in food-contact materials. The draft regulation mandates:

• A complete prohibition on PFAS in food packaging materials.

• BPA-free requirements for polycarbonate and epoxy resin-based food-contact products.

European Union: The European Union has also taken decisive action. Under recent regulations, BPA will be banned in food-contact coatings, varnishes, adhesives, inks, and plastics, with most applications required to transition by July 2026.

United States and Global Industry Initiatives: In addition to government regulations, major retailers and food service companies have voluntarily committed to eliminating PFAS and BPA from their packaging portfolios. These commitments have accelerated industry-wide efforts to adopt safer alternatives.

Challenges for the Industry

Despite the opportunities, several challenges remain:

• Performance trade-offs: PFAS- and BPA-based systems provide excellent durability and barrier properties that are difficult to replicate.

• Cost considerations: Alternative materials may initially be pricier.

• Supply chain adjustments: Raw material suppliers must also develop compliant chemistries.

• Regulatory fragmentation: Different regions may impose different restrictions, complicating global product development.

Conclusion

The global push to eliminate PFAS and BPA from food packaging represents a significant regulatory and technological transition for the paints and coatings industry. While these restrictions are driven by environmental and public health concerns, they are also accelerating innovation in sustainable coating technologies. Additionally, for coatings manufacturers, the transition away from PFAS and BPA will require substantial investment in research, reformulation, and regulatory compliance. However, companies that successfully develop high-performance, compliant alternatives will be well positioned to benefit from the growing demand for safe, sustainable, and future-proof packaging solutions.