DMF: three simple letters that are increasingly top of mind for actors across the synthetic materials value chain.
Dimethylformamide, to give it its full name, is a common industrial solvent and volatile organic compound (VOC). First developed in 1893, DMF has long been used in the production of synthetic materials, plastics, acrylic fibers, rubber, and polyurethane coatings. These are all key building blocks used in the manufacture of upholstery, shoes, bags, accessories, and various other consumer articles.
But DMF’s dominance is coming to an end, thanks to a growing body of research surrounding the potential dangers it poses to human health and the environment. Most at risk are chemical workers involved in the various stages of synthetic material production, particularly the treatment of traditional coagulated PU base layers and the application of the adhesive and final coating layers.
Meanwhile, the use of DMF in the production of synthetic articles may also have negative impacts on the environment. That’s because some synthetic material producers use an additional treatment stage to bring the DMF concentrations of the finished articles down to within legislative limits. This requires the extensive washing of products as part of the manufacturing process, which involves large quantities of water and energy. Significant resources are then required to treat and purify the subsequent industrial wastewater to prevent environmental contamination. So, the solvent is both harmful to human health and the environment, and a drain on precious resources.
With growing awareness around the solvent and its potential impacts, in 2012 the European Commission updated its Registration, Evaluation, Authorization, and Restriction of Chemicals (REACH) regulation, banning the presence of DMF in any article in concentrations greater than 0.1 mg/kg.
In November 2021, the European Chemicals Agency (ECHA) followed this up with new, reduced occupational exposure limits (OELs) for the substance, which come into force from December 12, 2023. Some uses of the solvent have been granted a longer transition period.
But regulatory pressure to eliminate DMF is also being matched by industry-led initiatives. For example, in November 2022, members of the Zero Discharge of Hazardous Chemicals (ZDHC) program announced the addition of DMF to its Manufacturing Restricted Substance List (MRSL) Version 3.0. ZDHC is a voluntary initiative of the textile, leather, apparel, and footwear industry.
This decision means that DMF will be effectively banned from intentional use in ZDHC-compliant facilities processing textile materials, leather, rubber, foam, adhesives, and trim components used in synthetic textiles, apparel, and footwear. The final deadline for compliance is November 1, 2023.
At Stahl, our sustainable innovation experts have been working hard to stay ahead of the changing regulatory and market landscape surrounding DMF. As part of our commitment to responsible chemistry, we maintain our own internal Restricted Substances List (RSL) that includes hazardous substances that are under scrutiny from regulators and market actors.
Effective planning on this issue has allowed our innovation teams to begin phasing out DMF from our synthetic material portfolios ahead of time – meaning Stahl is already well-positioned to offer a range of solvent-based resins, lacquers, and coatings for synthetics that fall well within the forthcoming ZDHC limits on DMF. This includes our Permuthane® EVO range of polyurethane resins, lacquers, and coatings.
Our solvent-based offering is part of Stahl’s broader range of synthetic coating solutions covering the different stages of coating production – from pre-skin to skin and adhesive layers, and from basecoat to topcoat finishes. This includes a variety of water-based (and therefore DMF-free by design) resins, lacquers, and coatings for synthetics, as well as our Permutex® EVO mechanical foam.
With the growing popularity of synthetic articles among consumers, you can expect the rules and regulations around DMF and other processing chemicals to continue evolving at lightning speed – and for good reason. At Stahl, we share the ECHA and ZDHC’s urgency to move toward a DMF-free future.
We’re already working on the next generation of DMF-free synthetic solutions, including water-based coagulation systems. And with more and more brands, consumers, and start-ups eager to see a cleaner value chain for synthetics, it’s never been more important to keep innovating for the years ahead. So, together, let’s help create a safe and healthy future for synthetics – with producers, materials suppliers, and brands collaborating to create a cleaner future for people and the planet.
Get the full story on Stahl’s advanced range of DMF-free solutions for synthetics and download the brochure here.