Polymers and polymer films serve as raw materials for single-use technology products like single-use bags and containers that are used in biomanufacturing. Since these products come into direct and indirect contact with the bioprocess their properties are particularly important. Also sustainability is increasingly important. In this article Ami Polymer, a manufacturer of a.o. polymer films, tubing, bags and single-use assemblies, discusses the developments in polymer chemistry and the possibility of Irgafos-free* films.
Polymer processing involves intense thermal and mechanical conditions that can accelerate thermo-oxidative degradation. During extrusion, moulding, film production, and repeated processing, polymer chains can undergo oxidation, resulting in molecular-weight reduction, discoloration, gel formation, changes in melt rheology, and deterioration of mechanical performance. Secondary antioxidants such as tris (2,4-di-tert-butylphenyl) phosphate have traditionally played an important role in controlling these degradation pathways.
By decomposing hydroperoxides generated during thermal and oxidative stress, phosphate stabilizers help preserve polymer integrity and improve processing stability. Their synergistic interaction with primary phenolic antioxidants provides additional protection by controlling both free-radical propagation and hydroperoxide accumulation. This combination supports improved colour retention, melt stability, processing consistency, and product quality across applications including polyolefin films, packaging materials, moulded components, and recycled polymers.
However, increasing requirements for low-migration, high-purity, recyclable, and sustainable materials are encouraging the polymer industry to explore alternatives. During processing and storage, phosphite stabilizers can undergo oxidation or hydrolysis, generating transformation products and progressively reducing their stabilization capacity. Migration of additives and their transformation products is particularly important in food-contact materials, pharmaceutical packaging, medical devices, and other sensitive applications.
Emerging technologies, including organophosphonite stabilizers, polymeric antioxidants, multifunctional stabilization systems, reactive antioxidants, and bio-derived additives—are being investigated to provide effective polymer protection while reducing migration and improving hydrolytic stability and sustainability.
This research paper has been published on the World Research platform, providing insights into emerging developments in polymer stabilization and antioxidant technologies: https://doi.org/10.5281/zenodo.21696310
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* Irgafos® by BASF is a range of secondary antioxidants and hydrolytically stable phosphite processing stabilizers for plastics, fibers, and elastomers. These additives work synergistically with primary antioxidants to protect polymers from thermo-oxidative degradation during processing. Irgafos® 168 is tris(2,4-di-tert-butylphenyl)phosphite.