Halogen-Free Extrusion Aids Market- Clariant Launches PFAS-Free Polymer Processing Aids as Extrusion Industry Moves Away from Fluorinated Chemistry

Clariant AG launched its PFAS-free AddWorksTM polymer processing aids on June 5, 2025, targeting more efficient polyolefin extrusion with improved surface quality and reduced sharkskin. The launch comes as cable compounders, film converters, and masterbatch producers look for non-fluorinated processing solutions that can maintain extrusion performance without requiring major changes to existing production lines.

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By Shambhu Nath Jha, Principal Consultant, Fact.MR

The shift toward halogen-free extrusion aids is being shaped by two practical concerns: regulatory scrutiny of fluorinated chemistries and the processing challenges created by highly filled polymer compounds. In HFFR wire and cable formulations, high mineral loading can raise die pressure, torque, and surface defects. In packaging films, converters face growing pressure to document the chemistry used in processing aids.

This puts the focus on whether alternative additives can deliver measurable improvements on the extrusion line. Fact.MR's research finds that silicone-based aids are positioned at the center of this transition, while wire and cable remains the largest end-use industry.

Why are processors looking beyond conventional fluorinated aids?

The move is not simply about replacing one additive with another. Compounders need processing aids that work under specific resin, filler, temperature, and extrusion conditions.

Clariant's June 2025 AddWorksTM PPA launch specifically targets sharkskin reduction, surface quality, and extrusion efficiency. Dow followed with DOWSILTM 5-1050 PPA in September 2025, positioned as an alternative to fluoropolymer-based processing aids for film packaging. The two launches illustrate how suppliers are competing around measurable line performance rather than chemistry claims alone.

Fact.MR estimates that PFAS-free packaging conversion has a +1.8% impact on CAGR, making it the strongest identified near-term growth driver. HFFR cable extrusion follows with a +1.6% impact on CAGR.

This combination creates an important commercial link. Packaging converters are evaluating chemical compliance while cable producers are dealing with increasingly demanding extrusion conditions. Suppliers able to address both documentation and processing performance have a wider qualification opportunity.

Which applications are creating the largest opportunity?

Wire and cable is expected to account for 45.0% of the market in 2026, making it the leading end-use industry. HFFR wire and cable compounds represent another major concentration, with a projected 41.0% share of the target-compound segment in 2026.

The reason is closely tied to processing conditions. Flame-retardant cable compounds often contain high mineral loadings, which can make extrusion more difficult. Processing aids can help manage die pressure, torque, surface defects, and deposits while manufacturers maintain the required compound characteristics.

Surface defects and sharkskin are projected to represent 30.0% of extrusion problems addressed in 2026. Visible surface quality is especially important during film, cable-jacket, and profile qualification because defects can prevent a material from passing customer approval.

Analyst Perspective

"The commercial test is simple: the aid must keep a loaded compound moving without fluorinated chemistry. Demand is expected to move toward suppliers that prove lower die pressure, cleaner surfaces and sound documentation. Strong portfolios combine silicone, polyamide and organic polymer options with application trials that mirror real extrusion settings."

- Shambhu Nath Jha, Principal Consultant, Fact.MR

Market Snapshot

2025 market value: USD 1.6 billion.
2026 estimated value: USD 1.7 billion.
2036 forecast value: USD 3.5 billion.
2026-2036 CAGR: 7.7%.
Absolute opportunity: USD 1.85 billion by 2036.
Leading aid chemistry: Silicone-based aids, with 34.0% share in 2026.
Leading target compound: HFFR wire and cable compounds, with 41.0% share in 2026.
Leading end-use industry: Wire and cable, with 45.0% share in 2026.

The Halogen-Free Extrusion Aids Market is projected to grow from USD 1.7 billion in 2026 to USD 3.5 billion by 2036 at a 7.7% CAGR.

Browse full Report: https://www.factmr.com/report/halogen-free-extrusion-aids-market

What's Driving Near-Term Demand?

Regulatory and infrastructure developments are reinforcing the market's commercial case.

The EU Packaging and Packaging Waste Regulation entered into force on February 11, 2025, establishing requirements covering the manufacturing, composition, and reusable or recoverable nature of packaging placed on the EU market. This is relevant for converters reviewing materials and processing chemistries used in packaging production.

Grid investment is creating another demand channel. The U.S. Department of Energy announced approximately USD 1.9 billion in March 2026 for critical grid infrastructure upgrades, including work involving reconductoring and higher-capacity conductors. More cable production creates additional opportunities for processing aids that can stabilize highly filled HFFR compounds.

The UK provides another strong growth signal. Ofgem said in March 2025 that new rules opened early access to almost GBP 4.0 billion for transmission equipment and services. Fact.MR expects the UK market to record a 9.1% CAGR through 2036, the highest among the five countries highlighted in the report.

Where are the strongest country-level opportunities?

Country growth varies according to grid spending, packaging conversion, EV-related demand, and industrial extrusion activity.

United Kingdom: 9.1% CAGR through 2036, supported by grid investment and low-smoke cable conversion.
United States: 8.2% CAGR, supported by grid upgrades and PFAS-free packaging conversion.
Germany: 7.7% CAGR, driven by transmission-line approvals and industrial compounding.
South Korea: 6.9% CAGR, supported by grid-flexibility investment and EV-linked extrusion demand.
France: 6.5% CAGR, supported by grid spending and electric mobility.

The geographic spread matters for suppliers because qualification requirements are not identical across applications. Cable producers may prioritize smoke, flame, and surface performance, while packaging converters place greater emphasis on chemical documentation and food-contact considerations.

Who are the key companies in the market?

The competitive field includes suppliers with portfolios spanning silicone-based processing aids, polyamide systems, organic polymer technologies, masterbatch-delivered solutions, and other PFAS-free formulations.

Key companies profiled by Fact.MR include:

Clariant AG
Dow Inc.
Arkema S.A.
Ampacet Corporation
Avient Corporation
Tosaf Compounds Ltd.

Clariant's AddWorksTM PPA line is positioned around PFAS-free polyolefin extrusion, while Dow's DOWSILTM 5-1050 PPA targets film packaging as an alternative to fluoropolymer-based processing aids. Competition is increasingly centered on application testing, cable-grade qualification, food-contact documentation, surface quality, and evidence of lower die pressure.

Explore More Related Studies Published by Fact.MR Research:

Extrusion Aids Market: https://www.factmr.com/report/5415/extrusion-aids-market

Aluminum Extrusion Market: https://www.factmr.com/report/aluminum-extrusion-market

Polymer Reactive-Extrusion Additives Market: https://www.factmr.com/report/polymer-reactive-extrusion-additives-market

Grinding Aids Market: https://www.factmr.com/report/596/grinding-aids-market

About the Report

The Fact.MR study evaluates non-halogen process additives designed to improve melt flow, surface finish, die cleanliness, and extrusion stability.

Coverage includes:

Aid chemistry: Silicone-based; polyamide-based; oleochemical and wax-based; acrylic and organic polymer; hybrid non-halogen systems.
Target compound: HFFR wire and cable compounds; polyolefin films; engineering thermoplastics; filled masterbatches; recycled polymers.
Extrusion problem: Surface defects and sharkskin; die pressure and torque; die build-up; throughput limitation; plate-out and deposits.
End-use industry: Wire and cable; flexible packaging; building products; automotive; consumer and other extrusion.
Regions: North America; Latin America; Western Europe; Eastern Europe; East Asia; South Asia & Pacific; Middle East & Africa.
Forecast period: 2026 to 2036.

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About Fact.MR

Fact.MR is a global market research and consulting firm, trusted by Fortune 500 companies and emerging businesses for reliable insights and strategic intelligence. With a presence across the U.S., UK, India, and Dubai, we deliver data-driven research and tailored consulting solutions across 30+ industries and 1,000+ markets. Backed by deep expertise and advanced analytics, Fact.MR helps organizations uncover opportunities, reduce risks, and make informed decisions for sustainable growth.

This release was published on openPR.