Replacing Fluorosurfactants with a High-Performance, Sustainable Alternative

How Applied Chemistries developed a PFAS-free marine coating solution that exceeded performance benchmarks while meeting environmental compliance standards.

Client Challenge

Phasing Out PFAS in Marine Applications

A leading manufacturer in the marine sector approached Applied Chemistries Inc. to replace a fluorosurfactant-based formulation being phased out due to growing regulatory restrictions on PFAS compounds. The challenge was to develop a high-performance, environmentally safe alternative that could meet or exceed the performance of the legacy chemistry.

Our Approach

Developing a Sustainable Fluorosurfactant Replacement

Applied Chemistries combined advanced polymer chemistry, formulation science, and environmental compliance expertise to design a high-performance, PFAS-free marine coating solution. Through a structured process of research, synthesis, testing, and collaboration, we identified a new chemistry platform that delivered superior surface performance while meeting stringent regulatory and sustainability goals.

Market and Technical Research

Analyzed and reverse-engineered the top commercial fluorosurfactant-based products to understand performance drivers such as surface energy reduction, contact angle behavior, and stability in various substrates.
Identified key failure modes in non-fluorinated commercial alternatives, including poor substrate wetting, re-emulsification, and residue formation.

Advanced Polymer Synthesis and Functionalization

Developed a custom-modified polydimethylsiloxane (PDMS) backbone tailored for ultralow surface energy and enhanced spreadability.
Introduced hydrophilic and oleophobic side-chain functionality using platinum-catalyzed hydrosilylation reactions. This enabled both water repellency and surface anchoring across a wide range of materials.

Formulation and Sustainability Enhancements

Optimized concentration to create a highly active product at 5–10x the active level of the original formula—reducing packaging needs and freight costs.
Final formula maintained shelf stability >12 months with no observed phase separation or loss of efficacy.

Customer-Centered Commercialization

Collaborated closely with the client’s marketing and compliance teams to finalize GHS labeling, technical data sheets, and SDS documentation.
Provided in-field support for application testing and validated performance on multiple substrates.

Outcome

High-Performance, PFAS-Free Marine Product Launch

The client launched the reformulated product under their own brand, delivering a next-generation PFAS-free solution that set a new industry benchmark for performance and environmental responsibility.

Key Results

High-Performance, PFAS-Free Marine Product Launch

Performance

Exceeded fluorosurfactant benchmarks in wetting, contact angle (<10° on treated textile), and water/oil repellency tests (AATCC 22 & 118)

Technology

Custom functionalized PDMS polymer with advanced siloxane architecture

Environmental Impact

100% fluorine-free, VOC-compliant, and >60% packaging reduction

Compliance

Fully GHS and SDS-compliant; REACH- and TSCA-registered raw materials

Partner with Us to Create High-Performance, Sustainable, and Compliant Formulations

Whether you’re looking to replace PFAS-based chemistries or develop a sustainable, high-performance formulation for your application, our team is here to help. Contact us today to discuss your challenges and explore tailored solutions that meet your technical, environmental, and regulatory goals.

See How Formulation Drives Sustainability

This project reflects our Custom Formulation capabilities—developing high-performance, PFAS-free alternatives that meet stringent environmental and functional requirements without compromise.