PFAS-Free Packaging: What It Costs and Where to Buy It

The Cost Question

One of the first questions food business owners ask when learning about PFAS regulations is: "How much more is this going to cost me?" It is a fair question, and the answer is more encouraging than many expect.

PFAS-free alternatives now exist for virtually every type of food packaging used in restaurants, food trucks, catering, and packaged food operations. The market for PFAS-free packaging has expanded significantly since 2022, driven by state-level bans and growing consumer awareness. As demand has increased and more manufacturers have entered the market, prices have come down considerably.

The typical price premium for PFAS-free packaging ranges from 5% to 20% above conventional equivalents. For a small restaurant spending $500 per month on disposable packaging, that translates to an additional $25 to $100 per month — a manageable increase for most operations, especially when weighed against the cost of non-compliance.

Several factors influence the exact premium you will pay: your geographic location, order volume, packaging type, and supplier relationships all play a role. Businesses that buy in larger quantities or negotiate annual contracts often see significantly lower per-unit costs.

Cost by Packaging Type

The following table provides approximate per-unit cost ranges for common food packaging types, comparing conventional options (which may contain PFAS) against PFAS-free alternatives. These figures are based on publicly available pricing from major food packaging distributors as of early 2026 and represent mid-range order volumes (cases of 250–1,000 units).

As the table shows, the per-unit premium for PFAS-free packaging is generally modest. The highest percentage premiums tend to appear on the lowest-cost items (plates, cups), where even a few cents of difference translates to a larger percentage. In absolute dollar terms, the increase per unit is small across all categories.

PFAS-Free Alternatives

PFAS has traditionally been used in food packaging to provide grease and moisture resistance, particularly in plant-fiber-based products like molded fiber containers, paper bowls, and paperboard boxes. Several alternative technologies now achieve similar performance without PFAS.

PLA (Polylactic Acid) Coatings

PLA is a plant-based bioplastic derived from corn starch or sugarcane. Applied as a thin coating to paper or fiber packaging, it provides effective grease and moisture resistance. PLA-coated packaging is widely available and is one of the most common PFAS-free alternatives on the market. It is suitable for both hot and cold food applications, though it has temperature limitations (typically up to about 180°F) that make it less suitable for very hot liquids or oven use.

Wax Coatings

Plant-based and food-grade wax coatings (such as soy wax or palm wax) provide grease resistance on paper products. Wax-coated packaging is cost-effective and performs well for wraps, liners, and bags. However, wax coatings can affect the compostability of the packaging and may not hold up as well under very wet or high-temperature conditions.

Clay Coatings

Mineral-based clay coatings (kaolin clay) are applied to paper and paperboard to create a barrier against grease and oil. Clay coatings are non-toxic, compostable-friendly, and provide good performance across a range of temperatures. They are particularly common in pizza boxes and paper trays. The trade-off is that clay coatings can make packaging slightly stiffer and may not perform as well with very liquid or soupy foods.

Uncoated Bagasse and Sugarcane

Some molded fiber packaging made from bagasse (sugarcane fiber) offers inherent grease resistance without any coating at all. The natural fiber structure, when pressed and molded at high temperature, can provide adequate performance for many food types. Uncoated bagasse is the simplest PFAS-free option and is fully compostable, but it may not perform as well with very oily or liquid foods compared to coated alternatives.

Bamboo Fiber

Bamboo fiber packaging has gained popularity as a sustainable alternative that can be manufactured with natural grease resistance. Like bagasse, bamboo fiber products can be pressed into a variety of shapes and sizes. They tend to be slightly more expensive than sugarcane-based alternatives but offer good durability and a premium aesthetic that some food businesses prefer.

Where to Buy PFAS-Free Packaging

Finding PFAS-free packaging has become substantially easier as the market has matured. Most major food packaging distributors now carry PFAS-free product lines, and several specialty suppliers focus exclusively on PFAS-free and sustainable packaging.

PFAS Packaging Check maintains a supplier directory that highlights distributors and manufacturers offering verified PFAS-free food packaging. The directory is searchable by packaging type, geographic coverage, and certification status.

When evaluating a supplier, look for the following:

• Provides Certificates of Analysis (COAs). A supplier that proactively offers third-party testing documentation for their products is demonstrating transparency about PFAS content.
• Certified PFAS-free products. Some suppliers carry products that have been independently verified as PFAS-free by recognized testing organizations. Look for specific certifications rather than self-declared claims.
• Ships to your area. Packaging is heavy and bulky, making shipping costs significant. A supplier with a distribution center near your location can substantially reduce your total cost.
• Carries your packaging types. Not every PFAS-free supplier carries every product category. Verify that the supplier offers the specific items you need before investing time in the onboarding process.

Reducing the Cost Impact

While the per-unit premium for PFAS-free packaging is modest, food businesses operating on thin margins understandably want to minimize any cost increase. Several strategies can help:

• Buy in bulk. Per-unit costs drop significantly at higher volumes. If you have storage space, ordering larger quantities less frequently can reduce your effective cost per unit by 10–20% compared to small, frequent orders.
• Negotiate annual contracts. Committing to a supplier for a year (with agreed-upon volume targets) gives the supplier revenue certainty and often results in better pricing than order-by-order purchasing.
• Consider packaging redesign. Switching to PFAS-free packaging can be an opportunity to evaluate your packaging lineup overall. Could you use a single bowl size instead of three? Could you switch from clamshells to wraps for certain items? Simplifying your packaging inventory can offset the per-unit cost increase.
• Explore state transition grants. Some states that have enacted PFAS bans also offer financial assistance to small businesses making the transition. Check with your state's environmental agency or small business development center to see if grant programs are available in your area.
• Join a purchasing cooperative. Some restaurant associations and food business groups have formed purchasing cooperatives that aggregate buying power across multiple businesses. This gives small operators access to the volume discounts typically available only to large chains.

ROI of Switching

When evaluating the cost of switching to PFAS-free packaging, it is important to consider the cost of not switching. Penalties for PFAS food packaging violations vary by state but can range from $2,500 to $50,000 per violation, with some states treating each day of non-compliance as a separate violation.

Consider a restaurant spending $600 per month on disposable packaging. A 15% premium for PFAS-free alternatives adds approximately $90 per month, or $1,080 per year. Compare that to a single violation penalty that could exceed $5,000 — and in states with per-day penalties, the exposure could reach tens of thousands of dollars before the issue is resolved.

There is also a growing marketing advantage to PFAS-free packaging. Consumer awareness of PFAS has increased significantly since 2023, and a segment of customers actively prefer businesses that use PFAS-free packaging. Some food businesses have found that promoting their PFAS-free packaging as part of their sustainability story has a measurable positive impact on customer loyalty and willingness to pay.