3M's Exit from PFAS

Do we already need alternatives to PTFE, FKM, and FFKM?

Consequences of 3M (Dyneon) Exiting PFAS Production

On December 20, 2022, 3M Company, headquartered in St. Paul, Minnesota, announced that the globally operating corporation would phase out the manufacture of PFAS (per- and polyfluoroalkyl substances) by 2025.

3M Corporate Headquarters in Minnesota

This also affects its subsidiary Dyneon GmbH, which manufactures fluoropolymers and fluoropolymer additives and operates, among other facilities, a production plant in Burgkirchen, Bavaria, at the Gendorf Industrial Park.

➥ https://news.3m.com/2022-12-20-3M-to-Exit-PFAS-Manufacturing-by-the-End-of-2025

Components made from fluoropolymers are used by engineers and designers in virtually all industrial processes due to their outstanding material properties. In the field of sealing technology, their primary applications are found in machinery and plant engineering as well as in the chemical processing industry.

In particular, the TFM® product line from 3M subsidiary Dyneon® has long been regarded as the de facto industry standard for PTFE bellows and diaphragms.

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Stefan BockManaging director | bock machining gmbh
Expert Article on the Topic: 3M's PFAS Exit | Last Updated: January 24, 2023
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The discussion about the impact of PFAS on nature, the environment, and human health is not new. It has already led to the ban on the production of fluorosurfactants (PFOAs). However, numerous environmental scandals around the world have further increased pressure on manufacturers of fluoropolymers.

California Attorney General Rob Bonta, Image Source: www.kqed.org

On November 10, 2022, California Attorney General Rob Bonta filed a lawsuit against several companies, including 3M and DuPont (Teflon®), alleging the release of PFAS into the environment. At the same time, the Biden administration was developing comprehensive regulations aimed at protecting drinking water supplies across the United States.

➥ https://www.reuters.com/business/3m-stop-making-forever-chemicals-take-up-23-bln-charge-2022-12-20/

It can be assumed that 3M’s management decided to discontinue PFAS production in response to these substantial legal actions. Shareholders and analysts are likely concerned about potentially significant long-term liability and damages claims. Ultimately, the company appears to have concluded that the financial impact of exiting the PFAS business would be less severe than the potential costs associated with continued production.

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3M’s withdrawal from PFAS manufacturing is likely to have far-reaching consequences. On the one hand, environmental regulators and policymakers, both in the United States and internationally, may view this move as validation of their efforts and become even more determined in pursuing stricter regulations. On the other hand, competing manufacturers will need to assess whether, and under what conditions, continued production of fluoropolymers remains viable and desirable.

➥ https://www.youtube.com/watch?v=C0EUoCOEqmI

With the filing of this lawsuit, attention increasingly focused on 3M (Dyneon) and DuPont (Chemours), the two longest-established producers of fluorochemicals in the United States.

Chemours, a DuPont subsidiary, IPO on July 1, 2015, Image Source: www.plasticsnews.com

In addition, there are many other manufacturers involved in the production of PFAS-related materials. Most of them are based in Asia, particularly in Japan, India, and China.

Most environmental impacts occur during the manufacturing process and therefore primarily at the production site itself. Once a fluorinated compound has been polymerized into a plastic material, such as PTFE, it is generally considered safe for use in its finished form. As a result, the use of such materials, and therefore their import, is not expected to be subject to fundamental objections in the future.

Therefore, it will be up to public debate and policymakers in PFAS-producing countries to determine whether the manufacture of these substances will ultimately be prohibited there.

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Due to Dyneon’s leading market position in fluoropolymers, second only to DuPont Chemours, supply shortages are expected to intensify in the short term. According to company information, approximately 18,000 metric tons of fluoropolymers are still produced annually, and demand for these materials will need to be met through alternative sources no later than 2026. This development also affects fluoroelastomers (FKM and FFKM) as well as fluorothermoplastics, including PFA, FEP, and PVDF.

➥ https://www.3mdeutschland.de/3M/de_DE/presse-de/pressemeldungen/ganzemeldung/?storyid=f29c372a-a0ce-4ba7-96b3-758490c120d4

TFM® in particular is specified as the required material in numerous technical component datasheets. Approval processes and qualification testing for alternative materials are complex, costly, and time-consuming. It can therefore be expected that the already strained market will see even stronger demand for traditional Dyneon products such as TFM® 1700 and TFM® 1750.

3M™ Dyneon™ PTFE TF 1750 Powder, Image Source: www.3mdeutschland.de

➥ https://multimedia.3m.com/mws/media/802319O/3m-dyneon-tfm-modified-ptfe-brochure.pdf

In fact, demand for fluoropolymers has steadily increased over the past several decades. If 3M proceeds as planned with its withdrawal from PFAS manufacturing in 2025, the volumes previously supplied by the company will be missing from the global market.

It is therefore highly likely that prices for all grades of PTFE will increase significantly in the future, while supply availability becomes increasingly constrained. As history has shown, psychological market factors could amplify this effect substantially.

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PTFE seals are widely used as universal problem solvers due to their outstanding material properties. Among other advantages, PTFE offers exceptional chemical resistance, a low coefficient of friction, and reliable performance at elevated temperatures. As a result, customized PTFE solutions are used extensively in the chemical industry, food and beverage processing, medical technology, and the pharmaceutical sector.

PTFE Bellows and Diaphragms, Image Source: bock machining gmbh

These components are typically subject to time-consuming development and approval processes. If Dyneon materials need to be replaced in the future, such transitions will likewise require extensive testing and validation.

Seals are typically among the most critical components in any industrial system. As a result of the discontinuation of Dyneon PTFE products, prompt and decisive action by both procurement and engineering departments is essential and urgently required.

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As already described in my blog, alternative materials that do not contain PFAS are already available.

➥ https://www.bock-machining.de/pfas-die-einschraenkungen-koennten-weiter-gehen/

The material that is most similar to PTFE in terms of its molecular structure is UHMW-PE (PE 1000). Instead of fluorine atoms, hydrogen atoms are attached along the long carbon chains. As a result, properties such as chemical resistance, low coefficient of friction, and physiological inertness are nearly comparable.

uhmw-pe molecular chain

Chemical Structure of UHMW-PE, Image Source: bock machining GmbH

The wear resistance of virgin polyethylene is estimated to be approximately 100 times greater than that of pure white Teflon® (!). As a result, fillers can generally be eliminated in dynamic sealing applications where the seal is subjected to abrasive wear.

Its mechanical strength and resistance to deformation under load are also superior. As a result, multifunctional components can be designed more easily and can perform additional functions. For example, wrench flats, threads, and clamping features can often be integrated directly into the component without the need for additional parts.

Interestingly, the flexural fatigue strength of ultra-high-molecular-weight polyethylene (UHMW-PE) is also in the same range as that of polytetrafluoroethylene (PTFE). As a result, the material can offer a nearly 100% replacement potential for applications such as bellows and diaphragms.

The only limitation is temperature resistance. Manufacturers typically specify a continuous service temperature of approximately 80 to 85°C (176 to 185°F).

Nearly all seals, bellows, and diaphragms made from PTFE or PTFE compounds can be replaced relatively easily by virgin UHMW-PE (Enduflon P1) for operating temperatures up to approximately 85°C (185°F), while eliminating the use of PFAS-containing materials.

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Fluoroelastomers such as FKM (e.g., Viton®) and FFKM (e.g., Kalrez®) are elastomer compounds in which the polymer molecules are partially or fully shielded by fluorine atoms from chemical attack. The result is significantly improved resistance to aggressive substances such as acids, alkalis, and solvents. At the same time, their usable temperature range is greatly extended, in some cases up to 300°C (572°F).

O-Rings bock machining gmbh

O-Rings bock machining gmbh

An additional advantage is that, in existing equipment, elastomer components made from standard materials such as EPDM or NBR can be replaced with minimal effort. This makes it easy to expand the application range of equipment such as pumps or valves, for example.

This could also become more challenging in the future, as the production of fluoroelastomers is associated with the use of more volatile PFAS substances. In addition, both FKM and FFKM compounds are themselves classified as PFAS.

This requires a creative engineering approach. If designers are willing to challenge the use of the elastomer component itself, alternative design concepts can be developed in which O-rings or diaphragms are replaced by components made from UHMW-PE (Enduflon P1, P16).

See also the following blog:

➥ https://www.bock-machining.de/o-ring-alternativen/

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Whether the fluoropolymer volumes currently produced by Dyneon will actually cease to be available only by 2026 remains to be seen. However, the availability of PTFE and other fluoropolymers is likely to decline significantly in the short term, as precautionary stockpiling and panic buying are expected to increase demand well before production is phased out.

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Price increases alone for PTFE, PFA, PVDF, and related fluoropolymers will force purchasing departments to take action. Adding to this challenge is the uncertainty surrounding the future ability to complete and deliver machinery and equipment on schedule. After all, seals are typically critical components that cannot simply be substituted without extensive testing, validation, and, in many cases, design modifications.

In most cases, these specialized components require extensive long-term internal and external testing. Such qualification programs must be carried out, documented, and validated, resulting in significant time and personnel commitments.

Therefore, every industrial company that uses sealing components made from fluoropolymers such as PTFE, FKM, FFKM, and similar materials should take action now and evaluate how these materials can be replaced over the long term. UHMW-PE is a high-performance, PFAS-free polymer that is already capable of replacing fluoropolymers in up to 90% of all applications today.

➥ https://www.bock-machining.de/live-webinar-7-pfas-freie-alternativwerkstoffe-zu-ptfe/

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What are your experiences? I look forward to receiving numerous responses!

Stefan Bock

Stefan Bock
Managing director

✉ s.bock@bock-machining.de
✆ +49 (0) 6023 94701 – 12

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