Development of Safe and Sustainable PFAS-Free Coatings: The BIO-SUSHY Approach

Per- and polyfluoroalkyl substances (PFAS) are widely used for their water and oil-repellent properties in various applications, including textiles, packaging, cookware, medical applications, electronics, etc. However, their persistence and toxicity present significant environmental and health challenges. The Horizon Europe BIO-SUSHY project aims to develop innovative coating solutions that align with the EU’s chemical strategy for sustainability, targeting a toxic-free environment.

BIO-SUSHY’s approach is built on three pillars: (i) research and innovation in hybrid organic/inorganic coating formulations, (ii) computational modelling to optimise performance and safety, and (iii) integration of the Safe and Sustainable by Design (SSbD) methodology. The developed solutions are validated in three strategic markets: textiles, food packaging, and cosmetic packaging.

Among the case studies, the application of sol-gel coatings to cosmetic glass containers demonstrates reduced waste (up to 25%), facilitates container reuse, and ensures user safety while meeting regulatory requirements. As part of its work on these coatings, BIO-SUSHY invests considerable efforts in implementing the Safe-and-Sustainable-by-Design (SSbD) framework, integrating sustainability strategies such as circularity and eco-design principles. Key to this approach is a multidisciplinary methodology based on computational tools and data-driven modelling, coupled with rapid release and screening technology, all embedded within a life cycle thinking perspective. In this way, the principles of SSbD are applied to organic and hybrid coating formulations to ensure that, from an early stage of the innovation process, both safety concerns and sustainability criteria are addressed so that more safe and sustainable value chains can be established.

This presentation aims at providing an overview of the project concept, methodology and main outcomes in BIO-SUSHY case studies.

The BIO-SUSHY project is funded by the European Union under the Grant Agreement Number 101091464. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the European Health and Digital Executive Agency (HaDEA). Neither the European Union nor the granting authority can be held responsible for them.