Rational design and supply chain wide implementation of safer alternatives to toxic chemicals for industrial applications

Abstract: The Toxics Use Reduction Institute (TURI) safer alternatives research combines rigorous performance testing with Pollution Prevention Option Analysis System (P2OASys) hazard scoring using authoritative information and embedding hazard prediction at the molecular level. TURI pragmatically applies basic science to make green chemical engineering feasible at scale, aligning with UN SDG 12 targets such as: 12.4 - Environmentally sound management of chemicals and wastes throughout their life cycle, reducing releases to minimize health/environmental impacts 12.5 - Substantially reduce waste generation through prevention and reduction 12.6 - Encourage companies to adopt sustainable practices Key examples include: + Biobased surfactants for semiconductor etchants, achieving equivalent performance to PFAS in oxidizing conditions, and P2OASys score reductions from 8.4 to 3.6–4.6. This led to over 90% customer switchover in less than 1 year, a 30X reduction in product price, and the avoidance of 5,000 pounds of annual PFAS emissions + Lead-free solder pastes used aqueous-synthesized nanoparticles, providing reliable bonding, reduced thermal stress, and enabling commercial viability across electronics supply chains + Hexavalent chromium-free conversion coatings were collaboratively developed for aerospace applications, reducing carcinogen exposure and enabling sector-wide adoption + Safer alternatives to halogenated solvents for critical cleaning, resulting in significant annual savings and <3-year ROI in advanced manufacturing facilities across Massachusetts + PFAS-free textile coatings utilized organic polymer systems for omniphobicity, delivering >150° water contact angles and >90% durability post-washing/abrasion, with significantly lower reproductive toxicity risks + Structure-activity relationships and Hansen Solubility Parameters guiding the selection and validation of alternative flame retardants and solvents for pharmaceutical applications. These innovations are examples of many TURI-led initiatives to curb pollution at its source, cut hazardous waste by millions of pounds annually across industries in Massachusetts, and save water and energy. They also show economic promise with short-term payback periods and have potential for global scaling, inspiring initiatives such as EU Substitution Centers. These successes result from collaboration with researchers and companies supported by TURI funding and oversight to ensure deployment and supply chain integration.