Moving toward fiber-based products free of PFAS: Industry response to regulations for paper packaging, hygiene and textile products

Per- and polyfluoroalkyl substances (PFAS) have played a critical role in the fiber-based industry for decades, primarily due to their ability to impart water and grease resistance to materials. However, increasing environmental and public health awareness has intensified regulatory scrutiny and driven a transition toward safer alternatives. Historically, the paper industry has depended on PFOA, PFOS, 6:2 FTOH, and PFBS to achieve the necessary barrier properties in food packaging, and these compounds continue to be detected in some products despite regulatory efforts to phase out PFAS. In the textile industry, over 72 distinct PFAS compounds have been identified, with PFOS and PFOA still prevalent. Similarly, in the hygiene products sector, FOA, 6:2 FTS, PFBA, and 6:2 diPAP have been detected in diapers, sanitary pads, and facemasks. Beyond legal liabilities for PFAS-related pollution, which have exceeded USD 54 million within the fiber-based industry, challenges linked to the disposal of PFAS-containing products, along with rising sustainability expectations from consumers, further intensify economic risks. Despite the comparable performance of emerging alternatives, treating paper with PFAS remains the most cost-effective option at USD 0.00012 per m². In contrast, the higher costs of biobased alternative coatings, ranging from USD 0.015 to 0.98 per m², could significantly impact cost structures unless the societal costs associated with PFAS pollution are accounted for. Estimates indicate that this transition could cost industry up to USD 12,500 million more than using PFAS treatments. Nonetheless, PFAS often deliver barrier performance that exceeds functional requirements in fiber-based products, particularly in single-use applications. Comparisons between PFAS and alternative technologies should therefore be based on the performance required for the intended application. Notably, major companies from the pulp and paper and textiles industries have already demonstrated that large-scale adoption of PFAS-free technologies is feasible while maintaining essential product performance. These findings indicate that with ongoing innovation and scaling, cost parity with PFAS-based products appears attainable.