Short answer: PTFE is the standard choice for non-stick and release applications at lower cost. PFA is selected when you need superior chemical resistance, thicker film builds, or performance in harsher operating environments. Both are Chemours Teflon-branded fluoropolymers and both are FDA food contact compliant.
PTFE and PFA are the two most commonly applied Teflon coating systems in industrial and food processing environments. They share the same Teflon brand name, but they are different polymers with different capabilities. Understanding where each one fits can save you time and money on your next coating project.
What are PTFE and PFA?
PTFE (polytetrafluoroethylene) is the original fluoropolymer — the material most people mean when they say "Teflon." It delivers excellent non-stick performance, low friction and easy cleaning. It is the workhorse coating for bakeware, food processing equipment, packaging machinery and light industrial components.
PFA (perfluoroalkoxy) is a more advanced fluoropolymer in the Teflon family. It offers stronger chemical resistance and the ability to build thicker, more continuous films. PFA is typically selected for chemical process equipment, pharmaceutical vessels, semiconductor components and applications where the coating needs to act as a genuine chemical barrier.
PTFE vs PFA at a glance
| Property | PTFE | PFA |
|---|---|---|
| Continuous service temp | 260°C | 260°C |
| Cure temperature | 380–390°C | 420–430°C |
| Total film build (DFT) | 25–35 µm | 35–200 µm |
| Chemical resistance | Good | Excellent — superior permeation barrier |
| FDA food contact | Yes | Yes |
| Application method | All-liquid spray (primer + topcoat) | Liquid primer + powder topcoat |
| Relative cost | Standard | ~30–50% more than PTFE |
Temperature performance
Both PTFE and PFA handle a continuous service temperature of 260°C, which covers the vast majority of food processing and industrial applications. The key difference is in cure temperature: PTFE cures at 380–390°C, while PFA requires 420–430°C. This higher cure temperature for PFA means the substrate needs to tolerate more heat during application, which can be a factor for certain aluminium alloys or temperature-sensitive components.
Film build and thickness
PTFE is applied as an all-liquid system (liquid primer plus liquid topcoat) and achieves a total dry film thickness of 25–35 µm. PFA uses a liquid primer with a powder topcoat, which allows thicker builds of 35–200 µm total. The thicker film gives PFA better mechanical durability and a more continuous barrier, which is why it is preferred in chemical exposure environments where permeation resistance matters.
Chemical resistance
This is where PFA clearly separates itself. While PTFE provides good general chemical resistance, PFA acts as a significantly better permeation barrier. In chemical process environments — acids, solvents, caustics — PFA prevents chemicals from migrating through the coating to the substrate. If your application involves ongoing chemical exposure beyond cleaning agents, PFA is usually the right call.
FDA compliance
Both PTFE and PFA coating systems are FDA compliant for food contact applications. If your requirement is food-safe non-stick performance and you are not dealing with aggressive chemicals, PTFE will do the job. There is no compliance advantage to specifying PFA purely for food contact purposes.
Cost considerations
PFA typically costs 30–50% more than PTFE for the same component. The cost difference comes from higher raw material costs and longer cure cycles at elevated temperatures. For applications where PTFE meets the technical requirements, there is no reason to over-specify PFA. Conversely, trying to save by using PTFE in a PFA-grade application usually leads to premature failure and more expensive rework.
When to choose PTFE vs PFA
Choose PTFE when:
- Non-stick or release performance is the primary requirement
- The application is food processing, bakeware or packaging equipment
- Chemical exposure is limited to standard cleaning agents
- Cost efficiency matters and the operating environment is not chemically aggressive
- Film build of 25–35 µm is sufficient
Choose PFA when:
- Chemical resistance and permeation barrier are critical
- The application involves acids, solvents, caustics or other aggressive chemicals
- You need a thicker, more robust coating build (35–200 µm)
- The component operates in a pharmaceutical, chemical or semiconductor environment
- Long-term protection against chemical attack is more important than upfront cost
Common mistake: Specifying PTFE for a chemically aggressive environment to save on coating costs. The coating fails sooner, the substrate corrodes, and the total cost of rework and downtime far exceeds the PFA premium. Get the coating system right the first time.
AST applies both PTFE and PFA systems
As Australia's only Chemours-licensed industrial fluoropolymer applicator, AST applies the full range of Teflon coating systems including PTFE, PFA, FEP, ETFE and ECTFE (Halar). We can assess your application, recommend the right system, and back it with a lifetime workmanship warranty.
Our major food processing clients — including Goodman Fielder, George Weston Foods, Allied Pinnacle, ARYZTA, Fonterra and Saputo Dairy — rely on AST for both PTFE and PFA coating work across bakeware, processing equipment and production lines.