Sustainable Adhesives: Eco-Friendly Without

Photo: Logan Voss / Unsplash

Industrial adhesives and sealants are essential for manufacturing, from automobiles to electronics, but their production and application often burden the environment. While traditional petroleum-based products offer high performance, their carbon footprint and toxicity are driving demand for change. Fortunately, innovative solutions—from bio-based raw materials to water-dilutable systems—are emerging, allowing technical parameters to be maintained while minimizing environmental impacts. How do these alternatives work, and what do they mean for manufacturing processes?

Why Is Sustainability in Adhesives and Sealants Crucial?

Adhesives and sealants are among the unobtrusive yet essential components in industrial manufacturing, construction, and consumer goods. However, their production and application represent a significant environmental burden—from raw material extraction through energy-intensive processing to emissions of volatile organic compounds (VOCs). Global adhesive consumption is estimated to be in the range of millions of tons annually, with traditional solvent-based or formaldehyde-based products contributing to a high carbon footprint. Sustainability in this segment is therefore not just a matter of ecological image but also economic efficiency: companies face increasing pressure from regulations (e.g., REACH, CLP) and customer demands for more environmentally friendly solutions.

Change is also coming from a technological perspective. Modern adhesives and sealants utilize biobased raw materials (e.g., vegetable oils, lignin), recycled polymers, or water-dilutable systems that minimize VOC emissions. However, maintaining performance—such as bond strength, temperature resistance, or chemical resistance—is crucial. Manufacturers are therefore investing in research into alternative polymers, such as CO₂-based polyurethanes or epoxy resins from renewable sources. Sustainability is thus ceasing to be a compromise and is becoming a competitive advantage.

Biobased Raw Materials: When Nature Replaces Petroleum

Traditional adhesives and sealants are often derived from fossil sources such as petroleum or natural gas. Their ecological alternative is plant-based raw materials, which reduce dependence on non-renewable resources and often lower the product’s carbon footprint. Among the most commonly used biobased components are vegetable oils (e.g., soybean, rapeseed), lignin from wood waste, or starches and cellulose. These materials are processed into monomers and polymers, which serve as the basis for adhesives with properties similar to their synthetic counterparts.

An advantage of biobased adhesives is not only their lower environmental impact but also often better biodegradability or compostability. For example, starch-based adhesives are used in the paper industry, where they enable material recycling without residual contamination. In sealants, plant oils replace synthetic plasticizers, thereby reducing the content of harmful phthalates. The challenge remains optimizing properties – biobased materials can be more sensitive to moisture or have lower thermal resistance, which requires combining them with additives or modifying polymerization processes.

Photo: Logan Voss / Unsplash

Water-based adhesives: The end of the solvent era?

Adhesives and sealants based on organic solvents are among the largest sources of VOC emissions, which contribute to air pollution and pose a risk to workers' health. Water-dilutable systems address these issues by replacing solvents with water, thereby significantly reducing the content of volatile substances. This trend is also supported by regulatory measures, such as the EU Industrial Emissions Directive, which restricts the use of harmful substances in industrial processes.

Water-based adhesives are used in a wide range of applications – from the woodworking industry (e.g., furniture production) to the automotive sector, where they are employed for bonding interior components. The advantages include not only a lower environmental impact but also easier handling and cleaning of tools. A potential drawback may be a longer drying time or sensitivity to low temperatures, though this can be addressed through additives or optimisation of application conditions. Modern formulations also achieve comparable strength and durability to traditional solvent-based systems.

Recycled and Circular Materials: A Second Life for Polymers

The circular economy is becoming a key topic in the adhesives and sealants sector. Instead of polymers ending up in landfills or incinerators, they can be recycled and reused as raw materials for the production of new products. Recycled polymers, such as polyethylene (PE) or polypropylene (PP), are processed into additives or binders that reduce the need for primary raw materials. This approach not only conserves resources but also lowers CO₂ emissions associated with the production of new polymers.

A challenge for recycled materials is ensuring consistent quality and performance. Polymers from recyclate may contain impurities or have different molecular properties, which affects bond strength or resistance to aging. The solution is a combination of recycled and primary raw materials or the use of special additives that improve compatibility and stability. For example, in the field of construction sealants, recycled polymers are used as fillers, reducing the consumption of new raw materials without compromising performance. The circular approach thus brings both ecological and economic benefits.

Photo: Alex / Unsplash

Low-emission adhesives and sealants: How to minimize volatile organic compounds (VOC)

Volatile organic compounds (VOCs) represent one of the biggest environmental challenges in the adhesives and sealants sector. They are released into the air during application and drying, contributing to air pollution, the formation of ground-level ozone, and potential health risks for workers. Modern low-emission formulations focus on reducing VOC content below 1% by weight, with some systems achieving even zero levels. The key to success lies in water-dilutable polymers, reactive diluents, or UV-curing systems that do not require solvent evaporation.

Choosing low-emission adhesives and sealants is not just a matter of ecology but also technical advancement. For example, epoxy systems with low VOC content use reactive modifiers that reduce viscosity without the need to add volatile solvents. Similarly, polyurethane sealants with a high solids content (over 90%) minimize emissions while maintaining elasticity and joint strength. It is important to verify certifications such as EMICODE EC1 PLUS or Blue Angel, which guarantee low emissions and safety for indoor environments.

Energy-efficient curing: Faster, cooler, more efficient

Traditional adhesives and sealants often require high temperatures or long curing times, increasing the energy demands of production processes. New technologies enable curing at room temperature or with significantly lower energy requirements. Examples include anaerobic adhesives, which cure in the absence of air, or UV-activated systems where polymerization occurs within seconds. These methods not only save energy but also shorten production cycles and increase productivity.

Another innovation is adhesives with microwave or induction curing, which enable targeted heating of the joint only, rather than the entire structure. This is particularly advantageous for large components, where conventional oven curing would be inefficient. For sealants, systems with rapid surface polymerisation are gaining ground, allowing immediate processing without long waiting times. When selecting, it is important to consider not only energy savings but also material compatibility and the required mechanical properties of the joint.

Durability and Lifespan: How Sustainability Extends Product Life

Sustainability in the field of adhesives and sealants is not just about eco-friendly raw materials, but also about extending the lifespan of final products. Adhesives with high resistance to moisture, UV radiation, or chemicals reduce the need for repairs and replacements, thereby saving resources and lowering the overall carbon footprint. For example, structural adhesives based on modified silanes combine the advantages of polyurethanes and silicones – offering strength, elasticity, and long-term stability even in demanding conditions.

Another important factor is resistance to ageing. Adhesives with antioxidants or UV stabilisers retain their properties for decades, which is crucial, for instance, in the automotive or construction industries. For sealants, systems with low modulus of elasticity are becoming popular, as they compensate for thermal expansion without cracking. When designing sustainable solutions, it is therefore essential to consider not only the ecological profile of the raw materials but also the long-term performance and reliability of the joint.

Looking for a more eco-friendly solution for your production?

GCG Group offers a wide portfolio of sustainable raw materials for adhesives and sealants, including biobased alternatives and low-toxicity systems. For each product, we provide detailed technical and safety data sheets to help you select the optimal solution for your applications. Contact us – or browse our catalog of over 1,300 products right away.