PFAS Regulations and Gasket Selection: What Technicians and Maintenance Teams Need to Know

PFAS regulations are reshaping the discussion about materials in sealing technology. Find out what engineers and maintenance professionals need to consider when selecting seals, including the use of PTFE, PFAS-free alternatives, and FPA-free materials.

For engineers, plant managers, and procurement teams, the debate over PFAS adds an extra layer of complexity to the selection of gaskets. Although current regulations do not yet prohibit fluoropolymers such as PTFE, the ongoing regulatory process means that when selecting materials, it is increasingly necessary to consider not only technical performance but also future regulatory compliance and long-term availability.

The following factors can help guide decisions regarding the selection of gaskets as regulations continue to evolve.

1. First, check the application requirements

The key considerations in selecting gaskets continue to be the operating conditions of the application. Engineers must determine the critical parameters before assessing the regulations. These include:

• Chemical resistance to the process medium
• Operating temperature
• Operational pressure and cyclic loading
• The flange design and surface roughness
• Long-Term Creep Relaxation

Fluoropolymers such as PTFE remain highly relevant because they perform well under a wide range of conditions, particularly in harsh chemical environments. In many chemical processes, however, it can be difficult to replace PTFE without compromising reliability.

2. Assess the material's regulatory exposure

Given the ongoing debate about PFAS, it is important for engineers to understand the regulatory classification of the materials they specify.

A useful distinction is:

• Fluoropolymer materials (e.g., PTFE)
• Non-fluorinated sealing materials, such as graphite or fiber-reinforced sheets

Although PTFE belongs to the PFAS family, the differences between fluoropolymers and other PFAS substances are increasingly being recognized in official discussions. Nevertheless, companies may choose to evaluate alternatives in applications where substitution is technically feasible.

3. Understand the difference between PFAS-free and FPA-free materials

Terminology is playing an increasingly important role in bid specifications.

• PFAS-free materials contain no fluorinated substances at all.
• FPA-free PTFE materials are produced without the use of fluorinated polymerization aids during manufacturing.

This distinction is relevant because FPA-free materials can address environmental concerns related to the processing of these substances, while maintaining the performance characteristics of PTFE in demanding applications.

4. Evaluate technically feasible alternatives

When PFAS-free materials are required or preferred, engineers should evaluate alternative packing materials based on operating conditions.

Typical alternatives include:

• Expanded graphite seals for high-temperature applications
• Fiber-reinforced seals for general industrial applications
• Elastomer sealing materials for systems operating at lower temperatures

However, these materials often have a narrower range of applications than PTFE. Graphite, for example, performs well at high temperatures but may not be suitable for highly oxidizing environments. Fiber-reinforced materials may have limitations when exposed to aggressive chemicals.

A thorough technical assessment is therefore essential to prevent the sealing performance or the reliability of the equipment from being compromised.

5. Consider reliability throughout the entire life cycle and the control of emissions

The performance of gaskets is directly linked to plant safety, emissions of harmful substances, and maintenance intervals. Materials that degrade prematurely or lose their sealing ability can increase the risk of leaks and operational downtime.

When evaluating alternatives, engineers must assess the following aspects:

• Long-Term Creep Relaxation
• Resistance to exhalation
• The Effects of Chemical Aging
• Expected lifespan

In many industries, maintaining leak-free systems remains the top priority. Material replacement must not compromise safety or compliance with environmental regulations.

6. Work closely with gasket manufacturers

Given the rapid changes in regulations, collaboration with material suppliers is becoming increasingly important. Manufacturers such as KLINGER offer the following:

• Up-to-date information on regulations
• Documentation on PFAS
• Information on alternative materials and their performance
• Advice on new product developments, such as FPA-free PTFE gasket materials (KLINGER products)

Close collaboration ensures that sealing solutions meet both technical requirements and future regulatory expectations.

7. Key Points for Practice

At this stage of the PFAS debate, selecting gaskets requires striking a balance between performance, regulatory compliance, and future-proofing. Rather than implementing a blanket material replacement, engineers must evaluate each application individually and determine whether PTFE is still the most reliable solution or whether technically suitable alternatives are available.

This engineering-based approach helps ensure that flange connections continue to function safely and reliably, while also taking changing regulations into account.