Breakthrough PFAS-Free Processing Aid Targets Cleaner Polyolefin Extrusion

Last updated: September 4, 2026

Key takeaway: AddWorks™ PPA 101 FG is Clariant’s organic, PFAS-free processing aid for polyolefin extrusion. The company says it can control melt fracture and die build-up while preserving important film properties. Converters should still validate dosage, clearance time, finished-film compliance and downstream performance on their own equipment.

Polyethylene film producers face an increasingly practical question: how can they move away from fluoropolymer processing aids without sacrificing output or surface quality?

Clariant is positioning AddWorks™ PPA 101 FG as one answer. In a technical article published on September 3, 2026, the specialty chemicals company described the additive as a 100% active, fine-grain processing aid based on proprietary organic material technology. It is intended primarily for polyolefin film extrusion and contains no intentionally used PFAS, silicone, polysiloxane or inorganic substances, according to Clariant.

The product is not simply being marketed around chemistry. Its commercial case rests on whether it can solve two costly extrusion problems: melt fracture, often called sharkskin, and material build-up at the die.  PFAS-free processing aid

Why polymer processors are looking beyond fluoropolymers

Processing aids reduce friction and flow instability where molten polymer meets the die surface. Fluoropolymer-based products have performed this role for decades, particularly in linear low-density polyethylene, or LLDPE.

Regulatory and customer requirements are now changing formulation decisions. The EU Packaging and Packaging Waste Regulation began applying on August 12, 2026. Among its provisions are concentration limits for PFAS in food-contact packaging. This is not a blanket prohibition on every PFAS use in every polymer application, but it makes chemical composition and supply-chain evidence more important for packaging producers serving the European market.

A PFAS-free processing aid can therefore support formulation simplification and future planning. It does not, by itself, establish that a finished package complies with every applicable law. Compliance depends on the complete formulation, the finished article, its intended use and the relevant jurisdiction.  PFAS-free processing aid

How AddWorks PPA 101 FG is designed to work

According to Clariant, AddWorks PPA 101 FG lowers the apparent shear stress at the die wall. That raises the critical shear rate at which surface defects appear, potentially allowing an extrusion line to operate at a useful output without visible melt fracture.

The company reports that sharkskin removal generally begins 20 to 40 minutes after start-up. The exact clearance time depends on the resin, equipment, film structure, processing settings and let-down ratio—the concentration of the processing aid in the final formulation.

Clariant says performance at a 0.2% let-down ratio was close to that of conventional fluoropolymer PPAs in its critical shear-rate testing. It also gives a typical working range of 0.1% to 0.3%, which is higher than the dosage commonly associated with some fluoropolymer aids. For that reason, the product should not be treated as an automatic one-for-one substitution.

The additive can be introduced directly through the host resin, formulated into a concentrate or delivered through a masterbatch. Clariant says it has worked in both Ziegler–Natta LLDPE and more demanding metallocene LLDPE formulations.

What the reported production benefits could mean

The most immediate benefit is the removal of sharkskin. A smoother extrudate can improve the appearance of film and reduce the need to slow a line to stay below the onset of melt fracture.

Die build-up is the second target. Deposits at the die can lead to defects, cleaning stops and lost production time. Clariant says the additive reduces build-up, with results influenced by concentration and process conditions.

The company also reports no negative effect in its tests on film optics, coefficient of friction, dyne level or tensile properties. It says the treated films remained compatible with corona treatment, printing, lamination and heat sealing. These are supplier-reported findings, not a guarantee across every resin package or converting line.

The absence of silicone and polysiloxane may matter to converters concerned about line contamination, surface treatment or adhesive bonding. This differentiates the product from some non-fluorinated alternatives that rely on silicone chemistry.  PFAS-free processing aid

Where the additive may fit

Blown LLDPE film

Packaging, agricultural and construction films are the clearest target markets. Examples include consumer and industrial packaging, mulch and silage films, greenhouse covers, vapor barriers and protective films. In these applications, a stable surface and consistent mechanical behavior are essential after extrusion as well as during it.

Cast LLDPE film

For cast-film operations, longer intervals between die cleanings could improve uptime. Clariant says the additive has been adopted in commercial cast-film production and can tolerate melt temperatures of 280°C or higher without creating chill-roll deposits. The supplier also reports no adverse effect on stretch behavior in industrial stretch film.

HDPE pipe

Clariant describes HDPE pipe as a proof-of-concept application rather than a fully established use. Early regional trials reportedly produced efficient processing and smooth internal pipe surfaces. That wording matters: the available public information supports further evaluation, not a broad performance conclusion for pipe production.

Food-contact status requires application-specific confirmation

Clariant reports food-contact clearances or listings under the US FDA framework, EU plastics rules, Mercosur requirements, China’s GB system and Japan’s positive list. It also describes the product as non-hazardous and not requiring a hazard label under the EU CLP framework.

Converters should obtain the current product data sheet, safety data sheet and food-contact declaration for the exact grade and manufacturing region. A raw material’s regulatory status does not replace migration testing, good manufacturing practice or a compliance assessment of the finished package.  PFAS-free processing aid

What converters should test before changing formulations

An effective trial should compare the candidate with the current processing aid under controlled conditions. Useful measurements include:

• time to eliminate melt fracture;

• output and head pressure at matched settings;

• die build-up and cleaning interval;

• film haze, gloss and surface uniformity;

• coefficient of friction and dyne retention;

• print, laminate and heat-seal performance;

• tensile and stretch behavior;

• total cost at the required dosage; and

• analytical and documentary evidence for the finished product’s target market.

This testing is especially important because Clariant says minor process adjustments may be needed and dosage can differ from a fluoropolymer-based PPA.

A credible option, with validation still essential

AddWorks PPA 101 FG reflects a larger shift in plastics processing: environmental and regulatory pressure is accelerating the search for alternatives, but production performance remains the deciding factor.

On the evidence publicly available, the product offers a technically plausible PFAS-free route for controlling melt fracture and die build-up in LLDPE film. Its claimed thermal stability, neutral effect on film properties and lack of silicone widen its potential usefulness.

However, most detailed performance information currently comes from Clariant. Processors should treat the figures as a basis for line trials, not as universally transferable results. A successful switch will depend on the resin, formulation, equipment, operating window and end-market compliance requirements.  PFAS-free processing aid

 

Frequently asked questions

What is AddWorks PPA 101 FG?

It is Clariant’s fine-grain, organic polymer processing aid for polyolefin extrusion. The supplier says it contains no PFAS, silicone, polysiloxane or inorganic substances.

What problem does it solve?

It is designed to reduce melt fracture, or sharkskin, and limit die build-up during extrusion. Clariant also reports smoother film surfaces without material changes to key optical or mechanical properties in its testing.

Is it a drop-in replacement for a fluoropolymer PPA?

Not necessarily. Clariant says the chemistry is different, typical use levels are around 0.1% to 0.3%, and minor processing adjustments may be needed.

Can it be used in food packaging?

Clariant reports broad food-contact status in several jurisdictions. Manufacturers must still confirm current documentation and assess the complete finished package for its intended market and use.

Is HDPE pipe a proven commercial application?

The company reports encouraging proof-of-concept trials. The public evidence does not yet justify treating pipe extrusion as broadly validated.

Sources and editorial transparency

• Clariant: AddWorks PPA 101 FG technical article, September 3, 2026

• Clariant: AddWorks PPA 101 FG product page

• European Commission: New EU packaging rules start to apply, August 11, 2026

Struktol Unveils 2 Powerful Additives Transforming Recycled Plastics Odor Performance Globally