/Magazin
Safe alternatives to brominated flame retardants
Brominated flame retardants are increasingly under pressure – their risks to the environment and health are too great. In this article, we show which halogen-free alternatives are available today.
Brief Overview
Brominated flame retardants have been under criticism for years: while they are effective at stopping fire, they also pose significant risks to both people and the environment. Strict regulations and rising awareness of sustainability make it clear – new solutions are needed. In this post, we'll take a look at modern, halogen-free alternatives like APP, ATH or MDH – and explain why our preference is for expandable graphite. This additive combines safety, sustainability, and technological precision like almost no other.
Legal Pressure
Regulations such as REACH and RoHS are driving the shift towards safer alternatives.
Expandable Graphite Alternative
Effective, halogen-free, versatile – why we choose expandable graphite.
Brominated flame retardants were long considered an effective solution for protecting materials in the event of a fire. But the price for this is high: many of these substances are suspected of being harmful to health and damaging to the environment. Nowadays, many representatives of this group are regulated or have already been banned.
In our article “Which flame retardants are toxic and hazardous to health?” we have explained why brominated and other chemical flame retardants must be critically assessed. In this article, we are deliberately looking forward: what alternatives are available? Which additives offer reliable protection – without endangering people or the environment? And which solutions have already proved themselves in practice?
Why alternatives are necessary – and what modern flame retardants must offer
Brominated flame retardants have been used for decades in a wide variety of applications – from plastics and textiles to electronics and building products. However, the downsides of these technologies can no longer be ignored: many brominated substances release toxic smoke gases when used or in the event of a fire, are suspected endocrine disruptors, are poorly biodegradable and remain active in the environment for long periods. This makes them increasingly problematic both from a health and an ecological perspective.
At the same time, regulatory pressure is growing. The European chemicals regulation REACH, as well as RoHS and POP regulations, are increasingly targeting brominated compounds. The consequences for internationally active companies are far-reaching. They are faced with the task of developing products that are not only functional, but also legally compliant, safe, and responsible.
At the same time, societal awareness of sustainability has increased significantly. Customers and business partners now expect not only high-performance materials, but also transparency and ecological responsibility, especially for sensitive additives such as flame retardants.
This results in a clear set of requirements for modern flame retardants: they not only need to reliably protect against ignition and fire spread, but also meet high environmental standards, integrate well into existing manufacturing processes, and ideally have no negative impact on the mechanical properties of the final product.
Whether in construction, electrical engineering or the automotive industry – the trend is towards solutions that offer sustainable protection throughout the entire lifecycle: from manufacture and use all the way to disposal. The good news: halogen-free alternatives such as expandable graphite are already up to this challenge.
An overview of halogen-free alternatives
The demand for sustainable, health-friendly flame retardant solutions is growing – in industry, construction, and consumer goods. More and more manufacturers are therefore relying on halogen-free flame retardants that combine a high level of protection with environmental compatibility. However, not every solution is suitable for every application, and especially when things get complex, more than just a single alternative is needed. What is needed is a material that offers reliable protection, is versatile, and fulfils the highest standards in safety, sustainability, and processability.
Ammonium polyphosphate (APP) – the classic among halogen-free additives
APP is one of the best-known halogen-free flame retardants, and is particularly often used in epoxy resins, wood coatings, and thermoplastic materials. It acts by forming a protective char layer and is especially popular in intumescent systems. APP scores points for its low costs and good availability, but it shows limitations in thermally demanding applications or in compounds with very specific mechanical performance requirements.
Aluminium hydroxide (ATH) – safe, but in high dosage
ATH is used as a non-combustible filler additive, mainly in cables, sealants, and plastic applications. It works by endothermic decomposition, where water is released to cool the source of the fire. The catch: ATH must be used in very high amounts, which can negatively affect the mechanical properties of the host material. It is therefore often not the first choice for complex or mechanically stressed components.
Magnesium hydroxide (MDH) – good thermal stability, but limited options
MDH works similarly to ATH but offers better heat resistance, making it suitable for applications with higher processing temperatures. In many formulations, it serves as a replacement for ATH, for example in cable sheathing or technical compounds. Like ATH, however, MDH is more a bulky filler and less an intelligent functional additive.
Expandable graphite – our preference for intelligent protection
Expandable graphite is, for us, much more than just an additive. It is a real high-tech mineral with a unique protective mechanism: under heat, the natural graphite expands to many times its original volume, creating a stable, foam-like protective layer. This barrier not only prevents fire from spreading, but also reduces the release of toxic smoke gases – a clear advantage over many other systems.
What makes expandable graphite so special:
- Effectiveness at low dosage: Reliable protection in the material is achieved from as little as 10% loading.
- Reduced heat input thanks to intumescence: Positive effects during fire testing in the Cone Calorimeter.
- Wide range of possible applications: From polyurethane foam and compounds to coatings.
- Thermally stable and REACH-compliant: Free from halogens, heavy metals, or critical by-products.
- Individually adaptable: Start temperature, particle size, expansion behaviour – everything can be precisely tuned.
- Evolves with requirements: We are constantly researching new grades – for new applications, markets, and challenges.
Many alternatives, but only one true favourite
The world of halogen-free flame retardants is diverse. Additives like ammonium polyphosphate (APP), aluminium hydroxide (ATH), or magnesium hydroxide (MDH) offer reliable solutions for specific applications and have their rightful place. Each of these substances fulfils a clearly defined purpose and many of them make a valuable contribution to greater safety and environmental compatibility.
But when we talk about flame retardancy, for us it is about more than just function. It’s about intelligent material solutions that develop and adapt alongside requirements. About additives that are easy to dose and can be developed further for new challenges. And this is precisely where our passion lies.
Our preference is for expandable graphite. For a material that not only inhibits flames but can also save lives in an emergency; that forms a protective barrier when exposed to heat and can be perfectly adapted to new applications. That is mineral, halogen-free and REACH-compliant – all without compromise on quality or performance.