Clay isn’t the first thing you’d expect as a PFAS alternative, but it’s showing serious promise.

A clay-based thin film, currently being tested for pharma blister packaging, has shown high barrier performance that could make it a strong PFAS-free packaging option for food, medical devices and other moisture and oxygen-sensitive applications.

With PFAS regulations tightening in the U.S. (since 2021) and a full ban proposed in Europe, the search for safer and scalable packaging materials is getting intense.

That’s what led us to explore lesser-known options, like this clay-based high gas barrier thin film being developed at Texas A&M University.

Here’s what makes it interesting (heads up, technical details ahead! 😛 )

• It’s a multilayer barrier film made from a polymer or cellulose base, coated with layers of a water-soluble polymer and vermiculite clay (which makes up 90% of the coating)
• Its unique ‘nanobrick wall’ structure forces gas molecules to take a longer path, significantly boosting its effectiveness.
• The result is a transparent, PFAS and halogen-free film with top-tier barrier performance.
• This clay-based film is just one of several PFAS-free alternatives we’ve come across.

My team has pulled together a few more alternatives that you might find relevant. Explore them here- https://slaternd.greyb.com/share/144b653b-1182-4471-bfec-c696f5c1dbd7

On Slate, you’ll find ongoing research, emerging solutions, and cross-industry innovations — all in one place.

You can also narrow your search by asking specific questions like:
“What’s a PFAS-free option for liquid applications?”
or
“Which materials offer high moisture barriers without halogens?”

If you’re exploring sustainable alternatives in packaging, this is a solid place to start. Let me know if you’d like help narrowing it down to what fits your specific needs.