From PC to BPA-Free PET: WK-901 Enables Safer Large-Capacity Water Bottles

Against this backdrop, WK-901 polyethylene terephthalate (PET) resin—specially engineered for large-capacity food packaging—is well-positioned to help companies transition from PC to PET in full compliance with evolving regulations.

The BPA Problem Behind Polycarbonate (PC)

Polycarbonate (PC) materials are widely used in 5-gallon drinking water bottles, yet concerns over their potential to release bisphenol A (BPA) under high-temperature conditions are growing. An empirical study conducted in the UAE (Al-Tameemi et al., 2024) systematically analyzed BPA migration from two local brands of PC water bottles. The findings revealed a significant increase in BPA concentration over time, particularly when bottles were stored in outdoor high-temperature environments, with levels reaching as high as 9.05 ± 2.30 μg/L. More importantly, the study found considerable variation between brands, indicating inconsistencies in material stability and production control across different PC suppliers.

EU Regulatory Developments and BPA Restrictions

On December 19, 2024, the European Commission officially adopted a proposal to prohibit the use of BPA in all food contact materials, citing its potential harmful effects on human health. This decision was followed by the publication of Regulation (EU) 2024/3190 on December 31, 2024, which repealed the earlier Regulation (EU) 2018/213 and amended the broader food contact plastics framework Regulation (EU) No 10/2011. The new regulation will take effect on January 20, 2025, marking a new era of stricter food contact material controls in the European Union.

Notably, BPA is a key monomer in the production of polycarbonate plastics. During real-world use—especially under high-temperature storage or transportation—BPA can gradually migrate from PC containers into water or food, posing a potential exposure risk. The updated legislation directly addresses longstanding concerns raised by the European Food Safety Authority (EFSA) regarding BPA’s endocrine-disrupting and immunotoxic effects, underscoring the EU’s firm commitment to protecting public health.

A Safer Alternative — Food-Grade PET

Against this backdrop, continued use of polycarbonate (PC) for drinking water bottles is increasingly challenged by both regulatory compliance and market access. In contrast, food-grade polyethylene terephthalate (PET) offers a BPA-free molecular structure, superior thermal stability, and low migration risk—making it a widely adopted and trusted material in bottled water and food packaging applications. With the official implementation of Regulation (EU) 2024/3190, replacing PC with PET has become a necessary step for manufacturers seeking export compliance and alignment with global sustainability standards.

WK-901: High-Performance PET Resin Tailored for Large-Capacity Bottle Production

The performance of PET raw materials plays a critical role in determining the quality and safety of large-capacity bottles. One key factor is intrinsic viscosity (IV). If IV is too low, mechanical strength is compromised; too high, and the material becomes difficult to process, reducing production efficiency.

Another crucial indicator is acetaldehyde (AA) content. Excessive AA can cause off-odors and affect the perceived safety of the bottled product. Crystallization behavior is also essential—improper crystallization speed or degree may lead to deformation, haze, or dimensional instability after molding, ultimately affecting product appearance and sealing performance.

Color consistency and low impurity content contribute to the bottle’s clarity and food-grade compliance, while stress crack resistance (SCC) ensures durability during transport and multiple reuse cycles.

In response to these challenges, Wankai New Materials has developed WK-901, a high-performance PET resin with an intrinsic viscosity of approximately 0.87. By optimizing molecular structure and polymerization processes, WK-901 offers a well-balanced combination of strength and processability, significantly reduced acetaldehyde release, excellent crystallization stability, and enhanced resistance to stress cracking. These features ensure stable performance during high-temperature stretch blow molding and meet the rigorous demands of large-scale production.

Most importantly, WK-901 is entirely BPA-free and complies with global food contact safety regulations, including those from the EU (EU 2024/3190) and the U.S. FDA, supporting a safe and compliant transition from PC to PET.

Production and Application Recommendations

While WK-901 is optimized for large-container PET production, proper equipment settings and process parameters are still essential. Factors such as mold design, preform heating temperature, blowing pressure, and cooling time all influence final product quality.

Manufacturers are advised to perform process validation and implement quality control protocols based on actual production environments. Through the right combination of advanced materials and optimized processing, WK-901 enables customers to tackle key challenges in large-bottle manufacturing while ensuring safety, consistency, and regulatory compliance.

Sustainability and Market Outlook

With the global shift toward green regulations and circular economy models, BPA-free and recyclable PET materials are emerging as the industry mainstream. WK-901 not only meets strict food safety standards but also supports post-consumer recycling, helping companies advance their sustainability goals.

Looking ahead, Wankai New Materials will continue to enhance the performance of PET solutions, driving innovation toward lower energy consumption and higher environmental standards—empowering partners to expand their market reach sustainably.