Safe alternatives to brominated flame retardants

Brominated flame retardants under criticism

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.

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.

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.