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The Dawn of a New Era in Cookware
2025 marks a new era for cookware and bakeware manufacturing. Meet Plaslon®, an ultra-durable, high-performance non-stick coatings that are truly sustainable, fully recyclable, and entirely free of PFAS or harmful chemicals. Developed by Fraunhofer, Germany. Available now.
For years, the cookware industry has been walking a tightrope, and with more and more countries banning PFAS, it has proven a somewhat real challenge, even until today, to innovate a coating that simply delivers top-notch performance, safety, and health without harmful chemicals like Teflon/PTFE, PFOS, PFOA, heavy metals, and other toxins baked into coatings and additives.
The answer so far? More often than not half-measures and marketing spin — technologies that often compromise performance, health, safety, or sustainability while claiming to do it all. Without any real breakthrough options it is understandable.
Let's discuss Plaslon®, the game-changing plasma-enhanced chemical vapour deposition (PE-CVD) coating technology developed from scratch by Germany's Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), that sets a new benchmark for durable non-stick performance, health, and sustainability.
Challenges of Existing Alternatives
Traditional PTFE-based coatings have long been the industry standard, but their well-documented health and environmental risks demand change. Many newer alternatives promise great durability, non-stick performance, and longevity while claiming to be PFAS. However, many claims often mislead consumers with vague labels like:
- "PFOA-Free" or "PFOA and PFOS-Free": While these terms suggest safety, they don't guarantee absence of other PFAS chemicals, creating a false sense of security.
- "Non-Toxic" or "Safe Nonstick": Broad, undefined claims that often obscure the continued use of PFAS like PTFE and other undesirable chemicals.
- "Eco-Friendly" or "Green": These labels imply sustainability without transparency about the actual materials used or proof of claim.
- "Advanced Nonstick Technology": On its own a vague term that often masks PFAS-based coatings.
- "Durable Nonstick Surface": Focuses on durability while sidestepping concerns about toxic materials.
- "Professional Grade" or "Chef's Choice": An empty marketing shell that suggests quality without disclosing materials and safety.
What makes Plaslon® Stand Out?
Plaslon®'s cutting-edge cold plasma coating technology offers many advantages over other non-stick coatings. Here a breakdown:
- PFAS-Free and Safe: 100% free of fluorine compounds, not subjected to potential future restrictions or bans related to PFAS, offering a safe and sustainable alternative.
- Unmatched Durability: With hardness comparable to enamel, Plaslon® resists cutting, scratching, and abrasion, thanks to its glass-like structure and strong substrate bonding.
- Superior Non-Stick Performance: Plaslon®'s low-energy surface ensures excellent, long-lasting non-stick properties, making it effortless to clean.
- Food-Safe: Tasteless and non-porous, Plaslon® is ideal for cookware, bakeware and many other food-contact applications.
- Substrates:: Plaslon® adheres to a wide range of materials, including stainless steel, glass, enamel, stoneware, and porcelain, offering unparalleled flexibility.
- Heat and Chemical Resistance: Plaslon® withstands continuous use at temperatures up to 250°C (500°F) and offers high chemical resistance due to its dense network structure.
- Sustainable Production: Plaslon®'s coating process is energy-efficient, using a cold plasma method that consumes minimal energy and avoids high-temperature baking. It’s also reproducible, thanks to precise control of the gas atmosphere.
- Cost-Effective and Scalable: With a thin coating of just 0.2 µm and low production costs, Plaslon® is designed for high volume production without compromising quality.
- Environmentally Friendly: Free of solvents, additives, and PFAS, Plaslon® promotes efficient energy-saving cooking. Plaslon® requires no decoating when it comes to end-of-life recycling.
- Advanced Composition: Plaslon® has a organically modified, glass-like structure that combines inorganic and organic networks, delivering flexibility, thermal shock resistance, and mechanical strength without fillers or colorants.
- Compatibility with Other Coatings: Plaslon® can be combined with advanced coatings like ta-C, DLC, and PLC to create multi-functional surfaces tailored to specific needs.
The Science Behind Plaslon®'s Performance
The exceptional performance of Plaslon® lies in its unique composition, advanced structure, and innovative manufacturing process. Here’s how:
Composition and Structure
- Organically Modified Glass-Like Solids: Combines organic and inorganic materials, featuring a high hydrogen-to-carbon (H/C) ratio for optimal performance.
- Inorganic Network (50-75%): Provides hardness, resistance to cutting and abrasion, and strong substrate bonding.
- Organic Network: Delivers flexibility and thermal shock resistance, ensuring the coating withstands temperature fluctuations without cracking.
- Clean Composition: Free of fillers, colorants, additives, reactants, and fluorinated compounds making it perfectly safe for food contact.
What Happens During Application?
PE-CVD (Plasma-Enhanced Chemical Vapour Deposition) is an advanced manufacturing process used to apply Plaslon®. How it's done is crucial to its unique properties and exceptional performance. Here’s a breakdown:
- Cold Plasma Process: PE-CVD uses cold plasma to deposit the coating at room temperature. This eliminates the need for high-temperature baking or sintering, making the process more energy-efficient and cost-effective compared to traditional methods.
- Vacuum Environment: The process is conducted under a fine vacuum, allowing ultra-precise control of the gas atmosphere. This ensures high reproducibility and consistent coating quality.
- Reaction Gases and Fragmentation: Reaction gases are fragmented in the plasma, enabling them to cross-link. This cross-linking is essential for creating a robust and durable coating.
- High Degree of Cross-Linking: The Plaslon® PE-CVD process results in extensive cross-linking within the coating, defining its mechanical, thermal, and chemical properties. This contributes to its hardness, durability, and resistance to chemicals.
- Gradient Layers: The process enables the production of gradient layers, allowing a gradual transition from strong adhesion to the substrate to excellent non-stick properties on the surface. This dual property enhances both performance and durability.
- Ready, Instantly: Unlike other coating processes, Plaslon®'s PE-CVD does not require annealing or cooling after application. This simplifies manufacturing, saves temporary storage space and reduces energy consumption drastically.
Versatile Application
Plaslon® is not limited to cookware or bakeware and can upgrade a large variety of materials and products, including:
- Enamel
- Glass
- Stoneware
- Porcelain
- Food Processing Equipment
- Kitchen Appliances
- Baking Equipment
- Cutting Tools
- Medical Equipment
- Industrial Applications
Smooth Integration, Precise, Mass Production Ready
Plaslon® is suitable for high to mass throughput. This rapid processing speed is achieved through:
- Loading and Unloading: Advanced automation facilitates speeds up substrate handling, reduces cycle times and enhances overall throughput.
- Efficient Deposition at Speed: Plaslon® is optimised for high-speed processing with accurate coating quality, ensuring ultra-precise deposition reliably at fast production rates.
- Design: The modular architecture of the Plaslon® PE-CVD systems enables easy scalability and customisation to meet specific production requirements, ensuring flexibility in mass production environments.
A Comparative Analysis
Let's compare Fraunhofer's Plaslon® PE-CVD technology with other common coating technologies out there today:
Non-Stick Performance
| Plaslon® by Fraunhofer IFAM | Superior (Long-lasting, consistent release) |
| PTFE / Teflon | Moderate (Performance degrades over time) |
| Ceramic (Sol-Gel) | Moderate (Wears down relatively quickly) |
| Silicone | Low (Inconsistent release properties) |
| Enhanced PTFE | Moderate (Improved, but still degrades) |
| Hard-Anodised + Non-Stick | Moderate (Non-stick coating can degrade) |
| Enamel | Good (Durable, but can chip) |
| Seasoned Cast Iron / Carbon Steel | Good (Requires proper seasoning) |
| Stainless Steel (Uncoated) | Very Low (Food readily sticks) |
Uncoated stainless steel is included as a popular alternative to non-stick cookware, particularly when used with sufficient oil or fat. Plaslon® can be coated on stainless steel.
Durability
| Plaslon® by Fraunhofer IFAM | Excellent (Highly durable coating, substrate independent) |
| PTFE / Teflon | Low (Wears out with regular use) |
| Ceramic (Sol-Gel) | Moderate (Durable, but prone to chipping) |
| Silicone | Low (Less durable than other options) |
| Enhanced PTFE | Moderate (More durable than standard PTFE) |
| Hard-Anodised + Non-Stick | Moderate (Hard-wearing aluminium, coating can wear) |
| Enamel | High (Very durable, unless chipped) |
| Seasoned Cast Iron / Carbon Steel | High (Very durable with proper care) |
| Stainless Steel (Uncoated) | High (Very durable metal) |
Lifespan
| Plaslon® by Fraunhofer IFAM | 8-10 Years (Long-lasting, regardless of substrate) |
| PTFE / Teflon | 2-4 Years (Typical lifespan) |
| Ceramic (Sol-Gel) | 1-2 Years (Short lifespan) |
| Silicone | 1-2 Years (Short lifespan) |
| Enhanced PTFE | 3-5 Years (Extended lifespan) |
| Hard-Anodised + Non-Stick | 2-5 Years (Coating lifespan varies) |
| Enamel | 5-10+ Years (Long lasting if not chipped) |
| Seasoned Cast Iron / Carbon Steel | 10+ Years (Potentially lifetime with care) |
| Stainless Steel (Uncoated) | 10+ Years (Potentially lifetime with care) |
Scratch Resistance
| Plaslon® by Fraunhofer IFAM | Excellent (Highly scratch-resistant, can be applied to stainless steel) |
| PTFE / Teflon | Low (Easily scratched by utensils) |
| Ceramic (Sol-Gel) | Moderate (Prone to chipping and scratching) |
| Silicone | Low (Easily damaged) |
| Enhanced PTFE | Moderate (Improved, but still vulnerable) |
| Hard-Anodised + Non-Stick | Moderate (Resists scratches better than PTFE) |
| Enamel | High (Very scratch resistant) |
| Seasoned Cast Iron / Carbon Steel | High (Very scratch resistant) |
| Stainless Steel (Uncoated) | High (Resistant to scratches) |
PFAS Content
| Plaslon® by Fraunhofer IFAM | PFAS-Free, Zero-F |
| PTFE / Teflon | Contains PFAS * |
| Ceramic (Sol-Gel) | Typically PFAS-Free ** |
| Silicone | Typically PFAS-Free ** |
| Enhanced PTFE | Contains PFAS * |
| Hard-Anodised + Non-Stick | Typically PFAS-Free *** |
| Enamel | PFAS-Free |
| Seasoned Cast Iron / Carbon Steel | PFAS-Free |
| Stainless Steel (Uncoated) | PFAS-Free |
* Whilst modern PTFE is often made without PFOA / PFOS (specific types of PFAS), it still contains other PFAS chemicals.
** While the primary components of ceramic (sol-gel) and silicone coatings are not PFAS, some formulations may include PFAS-containing additives, such as fillers, binders, or processing aids, to enhance certain properties.
*** The hard-anodised aluminium layer is inherently PFAS-free. The non-stick coating applied on top of the anodised layer is the area of concern. Some manufacturers offer PFAS-free non-stick coatings for use on hard-anodised aluminium.
Energy Required for Application
| Plaslon® by Fraunhofer IFAM | Minimal (Low-temperature plasma process) |
| PTFE / Teflon | Extensive (High-temperature sintering required) |
| Ceramic (Sol-Gel) | Moderate to Significant (Often requires curing/sintering) |
| Silicone | Moderate (Requires curing) |
| Enhanced PTFE | Extensive (Similar to standard PTFE) |
| Hard-Anodised + Non-Stick | Moderate to Extensive (Anodisation plus coating application) |
| Enamel | Extensive (High-temperature firing) |
| Seasoned Cast Iron / Carbon Steel | Minimal (Initial seasoning only) |
| Stainless Steel (Uncoated) | Not Applicable (No coating applied) |
Heat Resistance
| Plaslon® by Fraunhofer IFAM | Up to 250°C (482°F) |
| PTFE / Teflon | Up to 260°C (500°F) |
| Ceramic (Sol-Gel) | Up to 400°C (752°F) |
| Silicone | Up to 250°C (482°F) |
| Enhanced PTFE | Up to 260°C (500°F) |
| Hard-Anodised + Non-Stick | Up to 260°C (500°F) * |
| Enamel | Up to 450°C (842°F) |
| Seasoned Cast Iron / Carbon Steel | Very High (Suitable for very high heat) |
| Stainless Steel (Uncoated) | Very High (Suitable for very high heat) |
* Dependent on the specific non-stick coating technology used.
Chemical Resistance
| Plaslon® by Fraunhofer IFAM | Outstanding (Resists most chemicals, substrate independent) |
| PTFE / Teflon | High (Resists most chemicals) |
| Ceramic (Sol-Gel) | Moderate (Can be damaged by strong acids/bases) |
| Silicone | Moderate (Resists oils, degrades with some chemicals) |
| Enhanced PTFE | High (Similar to standard PTFE) |
| Hard-Anodised + Non-Stick | Moderate to High (Depends on the coating) * |
| Enamel | High (Resists most household chemicals) |
| Seasoned Cast Iron / Carbon Steel | Moderate (Reactive to acidic foods if seasoning is thin) |
| Stainless Steel (Uncoated) | High (Resists most household chemicals) |
* Dependent on the specific non-stick coating technology used.
Recyclability
| Plaslon® by Fraunhofer IFAM | Fully Recyclable, (substrate independent) |
| PTFE / Teflon | Not Recyclable (Typically landfilled) |
| Ceramic (Sol-Gel) | Not Typically Recyclable (Difficult to separate) |
| Silicone | Not Typically Recyclable (Difficult to process) |
| Enhanced PTFE | Not Recyclable (Typically landfilled) |
| Hard-Anodised + Non-Stick | Difficult to Recycle (Coating complicates process) * |
| Enamel | Difficult to Recycle (Coating complicates process) |
| Seasoned Cast Iron / Carbon Steel | Recyclable (As metal, seasoning is not an issue) |
| Stainless Steel (Uncoated) | Recyclable |
* The aluminium is recyclable, but the non-stick coating often hinders this or necessitates specialised processing.
Application Cost (Mass Production)
| Plaslon® by Fraunhofer IFAM | Low |
| PTFE / Teflon | Low |
| Ceramic (Sol-Gel) | Moderate |
| Silicone | Low |
| Enhanced PTFE | Moderate |
| Hard-Anodised + Non-Stick | Moderate to High |
| Enamel | Moderate |
| Seasoned Cast Iron / Carbon Steel | Low (Initial cost can vary) |
| Stainless Steel (Uncoated) | Not applicable |
Note
This table provides a general comparison of common non-stick coating technologies. Stainless Steel (Uncoated) is included as a benchmark due to its popularity. Cookware performance can vary depending on specific formulations, manufacturing processes, and usage conditions. Based on publicly available data and industry insights.
Frequently Asked Questions
Yes. Here's why:
- PFAS-Free: It is completely free of PFAS and fluorine compounds, thus avoiding the hazards associated with those materials.
- No Harmful Chemicals: It's made without fillers, colourants, additives, or catalysts.
- Low Environmental Impact: The cold plasma process means low energy consumption and minimal waste.
- Sustainable Production: The process complies with all relevant regulations.
- Durability: The long lifespan of products means fewer replacements, therefore less waste.
- Recyclability: The coating is fully recyclable.
- High Production Rate and Integration for Mass Production: PE-CVD processes generally offer high deposition rates, allowing for efficient and rapid coating of substrates. This efficiency is particularly beneficial in industrial settings where high throughput is necessary.
- Low Chemical & Energy Consumption: The cold plasma technology uses very little energy and chemicals.
- High Reproducibility: The process uses a vacuum for precise control of the gas atmosphere.
- Extended System Lifespan: The technology is very robust and designed for heavy industrial use.
- Production of Gradient Layers: Provides excellent coating adhesion and non-stick performance.
- High Degree of Cross-Linking: Enhances the thermal, mechanical, and chemical properties.
- No Annealing or Curing: Saves both time and energy.
- Cost-Effectiveness: Low energy, low chemical process and high production capacity make it very cost-effective.
- Differentiation: You will stand out in the market with extremely high performing, fully PFAS-free products.
- Demand: Meet a growing consumer preference for environmentally friendly, healthy products.
- Market Share: Capture the market share from those who prioritise both safety and sustainability.
- Brand Loyalty: Build trust with consumers through products that are both safe and good quality.
- Initial Investment: Slightly higher for the plasma control machinery / expertise.
- Efficient Production: Engineered for high production volume, reducing cost per unit.
- Lower Energy Consumption: Cold plasma lowers operating costs compared to traditional methods.
- Reduced Environmental Impact: Minimal chemical use, less waste, and lower greenhouse gas emissions.
- Long-Term Savings: The long lifespan of the product reduces replacement costs.
This process is designed to be cost-effective because:
- Very Low Chemical Usage: Uses small amounts of chemicals.
- Low Energy Consumption: No need for high-temperature ovens for baking or curing.
- High-Efficiency Production: Designed for automated high volume production with reduced costs.
- Low Cost Per Unit: Cost per coated item is significantly lower than that of its competitors.
- Robust and Durable Technology: Designed for a long service life.
Plaslon® PE-CVD is a more economical alternative:
- Low Material Costs: The process uses very small amounts of chemicals.
- Low Energy Consumption: No need for high-temperature ovens for baking or curing.
- Efficient High Volume Manufacturing: With automated production and handling.
- Lower Cost per Unit: Cost per unit is significantly (10-50%) lower.
- No Sintering, Curing: Saves both time and energy.
- No Additional Materials: There are no fillers, colourants, or additives required.
- No Curing/Annealing: The process does not require any curing or annealing after application.
- Rapid Deposition: The coating can be applied rapidly by a plasma-enhanced chemical vapour deposition method with the capacity to cover areas up to 500x400mm, with 800x800mm in development.
- Compatible with Automated Production: Designed to improve production throughput.
- Ultra-Thin Coatings: Requires very little time and material for deposition.
PE-CVD enhances cookware durability and longevity by forming ultra-hard, non-stick coatings that resist scratching, chipping, and wear from everyday use. The precise deposition process creates a robust bond with the cookware's surface, preventing flaking or degradation over time. This ensures consistent performance and extended product life of up to 10 years (following simple care instructions), even under high-heat and frequent use conditions.
No, significant variations exist among PE-CVD coatings. Key factors to consider include:
- Coating Composition: The chemical formulation of the coating directly influences its performance characteristics, such as wear resistance and non-stick properties.
- Deposition Precision: The accuracy of the deposition process is crucial for achieving uniform coating thickness and optimal adhesion, which are vital for the coating's effectiveness.
- Manufacturing Expertise: The experience and technical proficiency of the manufacturer play a pivotal role in ensuring consistent quality and durability of the coatings.
- Performance Consistency: Not all coatings offer the same level of performance; some may provide superior durability and functionality compared to others.
- Application Suitability: Certain coatings are specifically designed for particular applications, such as kitchenware, and may not be suitable for other uses.
Understanding these distinctions is essential for selecting the appropriate PE-CVD coating that aligns with your specific requirements.
Maintaining Plaslon® coated cookware is incredibly simple and hassle-free, thanks to its advanced non-stick properties and durable coating. Here’s how you can keep your cookware in pristine condition:
- Effortless Cleaning: Food rarely sticks to the surface, making cleanup quick and easy. A simple rinse or wipe with a soft sponge is often all that’s needed.
- Dishwasher Safe: The coatings are highly resistant to wear and tear, so you can safely clean your cookware in the dishwasher without worrying about degradation.
- No Special Tools or Cleaners: You don’t ever need harsh chemicals or abrasive scrubbers. Mild dish soap and a soft cloth or sponge are perfectly sufficient.
- Stain-Resistant: The ultra-smooth surface prevents staining, even with foods like tomato sauce or turmeric, ensuring your cookware stays looking new.
- Long-Lasting Performance: The durable nature of the coating means it retains its non-stick properties and appearance over time, even with regular use.
With Plaslon® coated cookware, maintenance is minimal, allowing you save resources, spend less time cleaning and more time enjoying your meals!
Certainly Not. PLASLON® neither contains nor develops any chemicals of concern.
- PFAS-Free: No harmful "forever chemicals." (no PFAS means no Teflon/PTFE, PFOA, PFOS, etc)
- Non-Toxic: Made without any harmful substances. Food safe.
- Regulatory Compliance: Manufactured to comply with all current and future regulations.
- Environmental Benefit: Low energy application with minimal waste. Fully end-of-live recyclability.
The Fraunhofer / Lotus Nano Difference
Lotus Nano collaborates closely with Fraunhofer IFAM on Plaslon® outreach and project delivery.
Fraunhofer's Institute for Manufacturing Technology and Advanced Materials [IFAM], part of Germany's Fraunhofer Society, is a pre-eminent European research institute specialising in materials science and surface technology. Fraunhofer IFAM developed Plaslon® to offer a high-performance PFAS-free alternative to existing cookware and bakeware coatings.
Your direct partnership with us guarantees:
- Direct Contract: All PLASLON® projects are directly fulfilled by Fraunhofer IFAM and Lotus Nano, with Fraunhofer IFAM serving as direct contract partner, ensuring first-class implementation and operational excellence with expert support throughout.
- Hard Science: PLASLON® is the result of over a decade of Fraunhofer IFAM's research and rigorous testing.
- Early Adoption Advantage: PLASLON® is ready for immediate integration worldwide on a first-come-first-serve basis. Avoid waitlisting.
Get in touch with us today to Request Technical Consultation & FREE Coating Samples!
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