Transition from Traditional Blowing Agents to Low-GWP Blowing Agents
- ial
- Mar 18
- 4 min read
The transition from CFCs to low global warming potential (low-GWP) blowing agents is transforming the global foam and insulation industry. Blowing agents are chemicals used to create the cellular structure in foam materials such as polyurethane and polystyrene, which are widely used in construction insulation, refrigeration appliances, automotive components and packaging. Traditionally used blowing agents have raised environmental concerns due to their contribution to greenhouse gas emissions, leading industries to adopt more sustainable alternatives.
Over time, blowing agents have evolved due to environmental regulations. Early generations included chlorofluorocarbons (CFCs), which were phased out due to their severe ozone-depleting effects. They were replaced by hydrochlorofluorocarbons (HCFCs), which had lower ozone depletion potential but still posed environmental risks. Hydrofluorocarbons (HFCs) then emerged as ozone-safe alternatives; however, they have very high global warming potential, making them significant contributors to climate change. This has led to the development of next-generation low-GWP blowing agents.
CFCs, particularly trichlorofluoromethane (CFC-11), were widely used as blowing agents for polyurethane foams due to their ability to produce low-density, closed-cell structures with excellent mechanical strength and superior thermal insulation. They also enabled tailored load-bearing properties in cushioning materials. However, CFCs were phased out under the Montreal Protocol because they deplete the ozone layer as UV radiation breaks them down, and they are also potent greenhouse gases.
HCFCs were introduced as transitional substitutes. Their lower chemical stability allows them to break down more readily in the lower atmosphere, reducing their ozone depletion potential (ODP 0.01–0.13). They have a lower environmental impact than CFCs, although regulatory measures have accelerated their phase out to further protect the ozone layer and climate.
HFCs replaced HCFCs as ozone-safe alternatives but have high global warming potential (GWP), leading to increasing regulatory restrictions. They are projected to contribute 0.25–0.40 W/m² radiative forcing by 2050. The industry is therefore shifting toward low-GWP alternatives such as HFOs and HCs. Mitigation scenarios suggest that phased reductions in HFC use could significantly lower emissions and climate impact by mid-century
Regulations Driving the Transition
In polyurethane foam production, HFC blowing agents are typically added to the polyol premix (B-component) and react with isocyanate (A-component) to create foam cells. Approximately 5–20% F-gas blowing agent is used in formulations, with 90–95% trapped inside foam cells for insulation. However, emissions can occur during manufacturing, product use and disposal, making these chemicals subject to strict environmental regulations.
Several international and regional regulations are accelerating the transition away from high-GWP hydrofluorocarbons (HFCs) toward environmentally safer alternatives.
AIM Act
The AIM Act, enacted in December 2020 and implemented from January 2022, aligns with the Kigali Amendment to the Montreal Protocol and authorises the US Environmental Protection Agency (EPA) to regulate HFCs. The law focuses on three main actions: phasing down the production and consumption of listed HFCs, managing HFCs and their substitutes, and facilitating the transition to next-generation technologies. Through an allowance allocation and trading program, the AIM Act aims to reduce HFC production and consumption by 85% by 2036. Key milestones include 40% reduction by 2024, 70% by 2029, 80% by 2034 and 85% by 2036. The policy also restricts HFC use in sectors such as commercial refrigeration, air conditioning, aerosols and foam products where low-GWP alternatives are available. Besides environmental benefits, the Act is expected to create 150,000 jobs and generate approximately $38.8 billion in annual economic benefits by 2027.
F-Gas Regulation
The European Union regulates fluorinated greenhouse gases (F-gases), including HFCs used in refrigeration, air conditioning and polyurethane foam production. The regulation began in 2006, was strengthened in 2015 (Regulation EU 517/2014) and further revised under Regulation (EU) 2024/573, effective March 2024. The EU framework uses a quota system to progressively limit HFCs placed on the market, targeting an 80% reduction by 2030 and a complete phase-out by 2050. Allocations will decrease from 60% of baseline production in 2025 to 15% by 2036. The regulation also bans several high-GWP products, including certain refrigeration equipment and aerosols, while promoting low-GWP refrigerants and natural alternatives.
Montreal Protocol and Kigali Amendment
The Montreal Protocol (1987) is a global agreement designed to protect the ozone layer by phasing out ozone-depleting substances such as CFCs and HCFCs. Over time, it has been strengthened through several amendments. The Kigali Amendment (2016) added HFCs to the list of controlled substances due to their high global warming potential. It mandates a global reduction of HFC production and consumption by 80–85% by the late 2040s, with developed countries beginning reductions in 2019 and developing nations freezing consumption around 2024–2028. This global phase-down could potentially prevent 0.3–0.5°C of global temperature rise by the end of the century.
Vienna Convention
The Vienna Convention for the Protection of the Ozone Layer (1985) laid the foundation for international cooperation on ozone protection. While it does not impose direct controls, it established the framework that led to the Montreal Protocol and subsequent agreements. The convention achieved universal ratification in 2009, demonstrating global commitment to addressing ozone depletion.
Kyoto Protocol
The Kyoto Protocol (1997), which entered into force in 2005, identified HFCs as greenhouse gases requiring emissions control due to their high GWP. It obligated developed countries to reduce greenhouse gas emissions and laid the groundwork for later agreements addressing climate-impacting gases. Participating developed countries achieved about a 22% reduction in emissions during the 2013–2020 commitment period compared to 1990 levels.
Market Shift in Polyurethane Blowing Agent Segments (2021–2030)
Market trends indicate a clear shift in blowing agent usage. HCFCs are expected to decline by around 50-60% between 2025 and 2030 as global phase-out commitments take effect. HFCs are projected to decrease by approximately 35–40% due to regulatory restrictions and climate concerns. In contrast, environmentally friendly alternatives are gaining traction. Hydrocarbons (HCs) (+45-50%) and hydrofluoroolefins (HFOs) (+50-55%) are experiencing strong growth due to their low GWP and effective insulation performance. Other alternatives such as methylene chloride and water-blown systems are also expanding as cost-effective and sustainable options. This transition reflects the industry’s broader move toward environmentally responsible chemical solutions.
Research for this study was carried out in late 2025 and early 2026. Data are provided from 2021 to 2030, with the base year 2025. The study reviews the consumption of additives in the polyurethane foam market split by end-use sectors across flexible and rigid foam.
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