The transition toward a toxic-free and circular economy necessitates a paradigm shift in the development of advanced coatings, Safety and Sustainability must be integrated alongside technical performance from the very beginning. This presentation explores how the Safe and Sustainable by Design (SSbD) framework has been translated into practice through two major European Horizon 2020 projects: ASINA and SUNSHINE.
In the context of the ASINA project, we demonstrated how design strategies were applied to develop high-performance antimicrobial and photocatalytic textile coatings. The core of the approach lies in the definition of a multidimensional "Design Space", where Key Decision Factors (KDFs), such as water-based, room-temperature synthesis and specific deposition parameters (spray coating), were systematically managed. These KDFs were mapped against a "Performance Space" defined by Key Performance Indicators (KPIs), including antimicrobial efficacy (100% bacterial depletion and DeNOx abatement), worker exposure levels, and nanomaterial release during the product’s life cycle. The selection of the most promising SSbD solutions, notably Ag-hydroxyethyl cellulose (AgHEC) and nitrogen-doped TiO₂, was supported by the ASINA Expert System (ES), a multi-objective optimization tool designed to balance safety, functionality, and cost-effectiveness.
In parallel, one of the case studies developed by the SUNSHINE project addressed the challenge of replacing hazardous PTFE-based anti-stick coatings in the bakery industry. A tiered SSbD approach led to the development of multicomponent nanomaterials (MCNMs), specifically core-shell structures like SiC@TiO₂ (Tier 1) and its further optimized alternative SiC@SiO₂ (Tier 2). The study highlights how modifying shell synthesis led to a 50% reduction in environmental impact and a 7% decrease in production costs, while ensuring strict compliance with EU food contact regulations through minimized ion migration.
By synthesizing the outcomes of both projects, this talk will illustrate how the integration of Life Cycle Assessment (LCA), exposure science, and early-stage toxicological screening can drive industrial innovation. The discussion will provide a strategic perspective for designing the next generation of coatings that meet industrial standards without compromising human health or environmental integrity.
