Most industry experts saw this one coming. In April 2024, the Environmental Protection Agency (EPA) issued a consumer ban on methylene chloride and new commercial restrictions on its use to improve workplace safety and protect human health. The final ruling goes into effect in Q3 2025, pushing manufacturers to find cost-effective, safe methylene chloride alternatives to stay in compliance.
Citing methylene chloride’s hazards, the EPA’s ban is wide in scope. Here’s a rundown on the compound, why it’s dangerous, and how to find the best alternatives to methylene chloride for your application.
What Is Methylene Chloride?
Methylene chloride (also known as dichloromethane, or DCM) is a volatile liquid used in a range of applications across industries. It is colorless and non-flammable in liquid form, although its vapors can be flammable at very high concentrations.
What Is Methylene Chloride Used For?
The American Chemistry Council (ACC) considers the ingredient “an essential compound,” which is certainly true. It is used to make consumer products and in manufacturing processing.
Common methylene chloride uses include:
- Paint stripping – Most consumers think of methylene chloride as a paint stripper. It can dissolve a wider array of paint coatings and compounds than most alternatives.
- Degreasing – It is used in many metal cleaning and manufacturing processes.
- Pharmaceuticals – Methylene chloride is used in pharma manufacturing.
Methylene Chloride in Food
While this practice is increasingly rare, methylene chloride has been used as an extraction solvent in food processing. The FDA has long-standing limits on the amount of methylene chloride that can remain in these products as a residue. The limits are designed to ensure levels will not impact human health. The most common food and beverage application of methylene chloride is caffeine extraction, which is why some consumer labels list it as an ingredient in decaf coffee and tea. Consumers have looked for decaf coffee without methylene chloride for years, and many brands have shifted away from using the compound.
Why Is Methylene Chloride Banned?
The EPA cited several potential methylene chloride dangers in its 2020 risk evaluation, which determined it presented an unreasonable risk to workers, consumers, and bystanders near the compound. The EPA’s list of methylene chloride hazards includes:
- Adverse effects on the liver
- Cancer risk
- Hypoxia
- Neurological damage
The evaluation found the compound met 52 of the 53 conditions that define a chemical’s risk as unreasonable. While OSHA requires personal protective equipment (PPE) when handling the chemical in the workplace, the EPA found those protections inadequate based on OSHA’s updated standards.
Alternatives to Methylene Chloride
Anticipating the EPA’s ban, manufacturers have already reformulated products, especially in the food and beverage industry. In addition to chemical-free processes like using Supercritical Carbon Dioxide (SCFE) as a solvent, several alternatives to methylene chloride extraction exist, including using ethyl acetate.
The industry has also developed alternatives to methylene chloride for paint removal and degreasing, relying instead on:
- Benzyl alcohol
- Bio-solvents
- Dibasic esters
- Isopropyl alcohol
Tilley Distribution has been working with our customers to identify the best methylene chloride substitutes for their existing and planned formulations. If you need assistance, contact our team today.
Adapt and Thrive with Tilley Distribution
In addition to our robust catalog of specialty ingredients, Tilley Distribution offers deep technical expertise. We assist with agile product formulation and development to empower resilience in fast-paced regulatory environments. Let us solve your pressing formulation, supply chain, and regulatory challenges; connect with a Tilley representative today to learn more.
