PFAS food packaging

Alabama PFAS manufacturing plant creates the climate pollution of 125,000 cars

The manufacturing plant responsible for PFAS-coated fast food packaging pumps out loads of a banned ozone-depleting compound along with "forever chemicals."

As evidence mounts that hamburger wrappers and other kinds of grease-proof packaging contaminate food with PFAS, states have started banning the toxic chemicals from food packaging.


Now, a new report provides yet another reason to remove PFAS, or perfluoroalkyl and polyfluoroalkyl substances, from food wrappers: climate and ozone pollution.

PFAS exposure is linked to immune and developmental system effects, increased risk of preeclampsia in pregnant women, increased risk of kidney and testicular cancers, and higher cholesterol, among other health effects. The Daikin America plant in Decatur, Alabama, which manufactures PFAS used to coat food packaging and textiles, released 240,584 pounds of the ozone-depleting chemical Chlorodifluoromethane (HCFC-22)—the global warming equivalent of one billion pounds of carbon dioxide—in 2019, according to a new report out Thursday from the nonprofit Toxic-Free Future.

Related: Global action on harmful PFAS chemicals is long overdue: Study

While HCFC-22, used in refrigeration, was banned at the start of last year under the Montreal Protocol, companies are still allowed to produce the compound as a byproduct of making other substances. Advocates say the new report highlights the need to close that loophole—and to use PFAS-free food packaging alternatives.

"The entire world is scrambling to reduce greenhouse gas emissions before their damage to our climate is beyond repair, yet we are letting a company dump hundreds of thousands of pounds of hydrochlorofluorocarbons into the atmosphere so that it can produce 'forever chemicals' that poison our communities?" Peggy Shepard, executive director of the nonprofit WE ACT for Environmental Justice, who was not involved in the report, said in a prepared statement. "Where is the justice in that?"

Far-reaching impacts of PFAS production

PFAS chemicals

Credit: Path of Toxic Pollution report

The impetus for the study was to learn more about the impacts of PFAS-containing products before they get to consumers or end up in landfills, Erika Schreder, science director of Toxic-Free Future, told EHN. The researchers found that there appears to be only one plant in the U.S. that makes PFAS for fast food packaging coating.

Daikin America, which also emits 55,000 pounds a year of the carcinogen tetrafluoroethylene, is the number two emitter in the country of HCFC-22 after the Chemours chemical manufacturing plant in Louisville, Kentucky, according to the report.

The authors also looked at the upstream pollution from the paper mills that coat food packaging with Daikin's PFAS product, estimating that each mill releases around 180 pounds of PFAS a day into waterways, with an additional 1,260 pounds ending up in sludge at wastewater treatment plants. "We have to remember that whenever PFAS is used, it's part of the drinking water contamination problem," said Schreder, noting that landfills have been a major source of PFAS pollution around the country.

Health problems near PFAS plant 

Decatur's PFAS manufacturing plant was originally built in 1961 by 3M, which sold the facility to Daikin America in 2014. Concerns about the plant, and other factories in the industrial area, have been around for decades, Brenda Hampton, a local resident and founder of Concerned Citizens of WMEL Water Authority, told EHN. Hampton and her mother both experienced kidney failure, and residents have come down with unusual forms of cancer and respiratory problems, she said.

Federal health authorities have tied elevated levels of PFAS in residents' blood to drinking water contamination downstream of that and another area plant, with Daikin agreeing to pay the local water authority $5 million in 2017 to help pay for a water filtration system, according to the report.

Last month, an employee at the Daikin America plant died after being exposed to dangerous chemicals on the job, local TV station WAFF-48 reported. Last year, OSHA fined the company $40,482 for alleged hazardous chemical management and respiratory protection violations, according to the new report.

"In this day and time, we should have [jobs and food] out there that won't be as toxic to people," said Hampton.

The report authors issue a number of recommendations, such as manufacturers paying for PFAS cleanup in affected communities, the EPA banning the production of HCFC-22 as an intermediary in PFAS manufacturing, and restaurant chains removing PFAS from food wrappers. With PFAS already banned from food packaging in states including Washington and Connecticut, some chains, like McDonald's, have recently agreed to phase out PFAS-coated packaging.

Daikin did not respond to requests for a comment on the new report.

Banner photo credit: Crispin Semmens/flickr

A group of people with their hands waving holding an LGBTQ flag in the air

Climate activism is getting a glow-up in Pattie Gonia’s environmental drag tour

In one-of-a-kind performances, drag queens and kings call for the for the protection of the planet — and all people.

A toddler holding a French flag standing next to the Eiffel Tower in Paris

Heatwaves in France cause around 5,400 deaths a year. Vulnerable communities are hit first

Two studies warn of the health impact of heatwaves in France, with worsening risks in poorly adapted housing and the most deprived areas.
An illustration with orange colored liquid balls that look like bubbles

Shape-shifting liquid stores energy, releasing it on demand

Northwestern chemists created a liquid that morphs into an energy-storing gel and resets with nothing but air — no metal, no plastic, no battery casing required.

A black and white photo of the front of the White House in Washington, DC

The White House’s energy policies are costing Americans dearly

Our wallets are taking the hit from an outdated focus on fossil fuels.
A view of a Puerto Rican street with multicolored buildings and cars and the ocean in the far distance

Inside the US government's push to divert Puerto Rico solar funds to a bankrupt utility

Documents show the Department of Energy bypassed normal procedures to steer hundreds of millions of dollars in Puerto Rico energy resilience funding away from rooftop solar projects.

A view of a petrochemical plant with a skyline in the background

Increasingly fierce storms are coming for the Texas coast. Is the petrochemical industry ready?

Galveston County is home to 22 refineries and chemical plants. The level of emergency preparedness varies widely.
Coal price investment trading crash arrow representing a falling industry.
Credit: Sergey Chuyko/BigStock Photo ID: 323446435

Trump administration’s coal investments breathe new life into plants with repeated violations

At least three of the 12 coal plants the Trump administration funded have been repeatedly cited for violating environmental regulations, amplifying public-health concerns.
From our Newsroom
Multiple Houston-area oil and gas facilities that have violated pollution laws are seeking permit renewals

Multiple Houston-area oil and gas facilities that have violated pollution laws are seeking permit renewals

One facility has emitted cancer-causing chemicals into waterways at levels up to 520% higher than legal limits.

Regulators are underestimating health impacts from air pollution: Study

Regulators are underestimating health impacts from air pollution: Study

"The reality is, we are not exposed to one chemical at a time.”

Pennsylvania governor Josh Shapiro speaks with the state flag and American flag behind him.

Two years into his term, has Gov. Shapiro kept his promises to regulate Pennsylvania’s fracking industry?

A new report assesses the administration’s progress and makes new recommendations

silhouette of people holding hands by a lake at sunset

An open letter from EPA staff to the American public

“We cannot stand by and allow this to happen. We need to hold this administration accountable.”

wildfire retardants being sprayed by plane

New evidence links heavy metal pollution with wildfire retardants

“The chemical black box” that blankets wildfire-impacted areas is increasingly under scrutiny.

Stay informed: sign up for The Daily Climate newsletter
Top news on climate impacts, solutions, politics, drivers. Delivered to your inbox week days.