Innovation
Fluorine-Free Coating
1. SITUATION
The quest for more sustainable packaging
Traditionally, achieving high barrier performance often meant compromising recyclability. Technologies such as additives or EVOH multilayer structures can provide excellent protection, but they also add complexity to the packaging structure and may create challenges for recycling.
As packaging producers prepare for a more circular future and new regulations such as the European Packaging and Packaging Waste Regulation (PPWR), the need for alternative barrier technologies is becoming increasingly urgent.
2. SOLUTION
Delta Engineering introduces fluorine-free plasma coating
At Delta Engineering, we offer multiple plasma coating solutions. For solvent barrier applications, our fluorine-based plasma coating complies with the most stringent PFAS requirements and can be applied to containers ranging from 0.1 to 220 L.
To meet the growing demand for fluorine-free solutions, we have developed a new proprietary low-pressure plasma process that deposits an ultra-thin carbon-based coating on the internal surface of the packaging. The coating enhances barrier performance while maintaining the benefits of a mono-material packaging structure.
The technology is currently being industrialized for 1 L and 5 L containers, with development for 20 L jerrycans already underway. Ultimately, we aim to extend the technology across a broad range of packaging formats and volumes.
The result is a future-ready solution that helps manufacturers combine performance, recyclability, and compliance in a single packaging concept.
3. BENEFITS
Future-proof compliance without PFAS concerns
The fluorine-free plasma coating creates an effective barrier against permeation and migration, making it suitable for a wide range of applications. The newly developed technology has already demonstrated excellent performance on 1 L and 5 L HDPE containers for demanding products such as fuels and solvent-based formulations.
Recyclability without compromise
Many conventional barrier solutions rely on additives or multilayer structures that complicate recycling. Our plasma coating technology applies an ultra-thin functional layer while preserving the mono-material nature of the packaging. This enables manufacturers to maintain recyclability while still achieving the required barrier performance.
Fast ROI through simpler packaging structures
On top of the sustainability benefits, the new plasma coating process also offers economic advantages. By replacing additives, fluorination processes, or complex multilayer structures, plasma coating can reduce packaging complexity and simplify production. Consequently, the process creates opportunities for faster return on investment.
Improved barrier performance for rigid packaging without fluorination
Our fluorine-free plasma coating technology helps manufacturers bridge the gap between performance, compliance, and circularity. By combining strong barrier properties, mono-material recyclability, regulatory readiness, and attractive economics, the technology offers a practical pathway towards future-proof packaging.
As development progresses from 1L and 5L containers to larger formats, we continue to push the boundaries of what barrier coating technologies can achieve.
Want to learn more?
Discover Delta Engineering’s plasma coating solutions for rigid packaging.
