Regulatory changes are coming for the world of “forever chemicals,” beginning as early as January 2026. Federal regulations have been simmering for decades, but states have their own  policies and what begins in a single state — say, California or New York — can often foreshadow nationwide policy. 

For manufacturers handling ingredients to make food, plastics, personal care, and chemicals, bans on PFAS and PTFE represent not just compliance risks but design inflection points. Here’s why ingredient automation systems must evolve, and how you can get ahead before mandates become enforcement.

Why PFAS and PTFE Are Targets

The term PFAS (per- and polyfluoroalkyl substances) covers thousands of synthetic chemicals known for resisting heat, grease, and moisture. For decades, they’ve been used across industries — from food processing to electronics — because of their durability. But that durability is what’s putting them under scrutiny. PFAS don’t break down easily in the environment, earning them the nickname “forever chemicals.”

One of the most common PFAS used in manufacturing is PTFE (polytetrafluoroethylene). It’s a fluoropolymer found in seals, gaskets, liners, and nonstick coatings. It performs reliably under harsh conditions, which is why it’s widely used in systems that handle aggressive ingredients or require hygienic, low-friction contact surfaces.

From Early Warnings to Regulation

In 1998, the Environmental Protection Agency (EPA) was first informed of the hazards of PFOS detected in human blood, along with a study showing that PFAS caused liver damage in rats. 

Later in 2006, the EPA Science Advisory Board stated that PFOA was a “likely human carcinogen.” By the 2010s, action plans began surfacing to set an enforceable legal limit for PFOA and PFOS in drinking water, but didn’t come to fruition until 2024 when PFAS drinking water standards were finally launched by the EPA.

While federal regulators began focusing on PFAS like PFOA and PFOS, states like California and New York began treating the entire class of PFAS, including fluoropolymers like PTFE, as potential targets for restriction or phaseout.

For manufacturers, that means evaluating where these materials show up in your ingredient handling systems and having a plan in place if replacements become necessary.

Upcoming Forever Chemical Enforcement

Track the latest PFAS legislation news on ManufacturingDive.com.

Impacts on Ingredient Automation Systems and Components

As PFAS regulations expand, many manufacturers are discovering just how embedded these materials are in their processes. Here’s what to keep in mind.

Gaskets, seals, valve linings, tubing, and hoses

PTFE’s nonstick, inert properties make it ideal for contact with aggressive or sticky materials. But in systems where those characteristics aren’t critical, alternative materials may be viable. The key is understanding your exposure points and how those materials perform under actual process conditions.

Surface coatings

PFAS-based coatings often improve cleanability or reduce friction in conveying lines and feeders. Today we do not apply PTFE or other PFAS based coatings to metal contact parts in our equipment and we do not plan to do so in the future. For manufacturers that currently rely on PFAS based coatings to improve cleanability or reduce friction, PFAS regulations are a good prompt to reassess what is truly necessary. In many cases, alternative surface finishes or design changes can help maintain throughput and hygiene while also supporting compliance and corporate sustainability goals.

Dust control systems

Even if a product does not intentionally include PFAS, its manufacturing may generate PFAS byproducts. In some applications we do supply PTFE coated filter bags where the product tends to build up on the filter media. As PFAS restrictions evolve, those bags will need to be replaced with non PFAS alternatives, and we will work with our filtration suppliers to identify suitable options. Manufacturers should expect increasing scrutiny of PFAS emissions and waste streams and plan upgrades to dust collection and disposal practices accordingly.

Supply chain disruptions and cost risk

As fluoropolymer use comes under pressure, availability may shift which impacts your supply chain. That means longer lead times or unexpected specification changes unless you’ve built flexibility into your equipment design.

Strategies for Manufacturers

There is no single substitute that can replace PTFE and other PFAS in every application, but there is a growing toolbox of materials and surface technologies that can reduce PFAS exposure without undermining performance. The right approach depends on process conditions, cleaning methods, and your risk tolerance.

Product contact surfaces and equipment finishes
Many manufacturers are looking at high performance polymers and PFAS free coatings instead of defaulting to fluoropolymers. Materials such as PEEK can be used for wear parts and structural components, while silicone based and other non fluorinated coatings can support cleanability where ultra low friction is not essential. Ceramic and ceramic hybrid coatings are also being used to create hard, smooth, easily cleaned surfaces in place of traditional nonstick systems.

Seals, gaskets, and bearings
In sealing and bearing applications, high performance thermoplastics such as PEEK, PPS, and PPSU are being applied where PTFE might previously have been specified by default. In some dry running or marginally lubricated situations, carbon graphite and other composite materials can deliver the combination of low friction and wear resistance that is needed without relying on PFAS based chemistries.

Chemical handling and transfer components
For components that see aggressive or sensitive materials, such as pumps, valves, manifolds, and piping elements, PEEK and PPS are increasingly used in structural and wetted parts when conditions are within their safe operating range. In more extreme corrosive or abrasive environments, ceramic linings and ceramic composites can provide inert, long lasting surfaces that avoid fluoropolymers altogether.

Low friction mechanical elements
Where low friction is the main driver, engineered polymers such as PEEK and selected carbon based composites can offer a balance of strength, dimensional stability, and sliding performance. For metal parts, DLC, diamond like carbon, coatings are used to achieve very low friction and high wear resistance without PFAS, especially in actuators, bearings, and other high cycle mechanisms.

None of these options is a universal direct replacement for PTFE. Most will need to be tested under your actual process conditions, including cleaning and sanitation, to confirm that they meet your hygiene, durability, and regulatory requirements.

If you're not sure where to start, we're here to help. AZO can review your current system, run lab tests on replacement materials, and develop retrofit-ready solutions that keep your operations compliant without sacrificing performance.

See our approach