Star Plastics Unveils PFAS-free CompoundsStar Plastics Unveils PFAS-free Compounds
The formulations are the first in a new category of products for the plastics compounder.
January 13, 2025

Star Plastics announced that it has released new polycarbonate compounds that are free from per- and polyfluoroalkyl substances (PFAS). The products are part of the company’s Orion engineering resins line and its reNova recycled resins portfolio.
The formulations are the first in a new category of products for the firm, said Star Plastics. Existing products carry UL 94 flame-retardant ratings of V0, V2, and HB. Compounds with additional UL ratings are in development.
PFAS, often called “forever chemicals” because they break down very slowly over time, exist in thousands of compounds and have been linked to harmful effects in humans and animals, according to the Environmental Protection Agency. Because of their ubiquity, however, it is challenging to determine the extent to which they may affect health. In any case, bans have proliferated across the globe, and many materials suppliers are racing to develop PFAS-free products.
For example, South Korea’s Samyang Corp. introduced a transparent PFAS-free flame-retardant polycarbonate suitable for automotive applications last year and Baerlocher USA unveiled developments in its PFAS-free polymer processing aid (PPA) technology at NPE2024. PPAs typically are used to improve processability of polymers during extrusion.
Star Plastics Technical Manager Bob Powers anticipates prolonged growth in the PFAS-free product category and said that his company is currently formulating products for other material grades and end uses. “This work fits in with Star’s origin as a post-industrial recycler, our reNova recycled resins with content validated by UL, and our rating by EcoVadis, the world's largest provider of business sustainability ratings. We are committed to making a difference by supplying a diversified set of sustainable compounds,” stressed Powers.
“By giving molders options in the materials they process, they can have a greater impact on preserving the environment and meeting their sustainability goals,” added CEO Daniel McMullen.
Star Plastics operates plants in Ravenswood and Millwood, WV, and has a global manufacturing footprint. The compounder serves a variety of industries including consumer electronics, electrical, lighting, appliances, transportation, packaging, furniture, industrial, and telecommunications.
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