They didn’t tell their employees. They didn’t warn consumers. And for decades, they claimed non-stick coatings were completely safe, even as they quietly removed exposed workers from production lines.
But behind the scenes, DuPont and 3M knew the truth.
By 1970, internal documents reveal they had evidence that the chemicals used to make non-stick coatings — known as PFAS — were “highly toxic when inhaled and moderately toxic when ingested” (Gaber et al., 2023). Instead of alerting regulators or the public, they buried the data, distorted the science, and delayed oversight for over 40 years.
Fast forward to today, every time you fry an egg or stir a sauce, your pan may be serving up more than food. New research shows non-stick coatings can shed thousands of invisible plastic fragments into your meal, and scientists are now detecting these same particles inside human bodies (Luo et al., 2022; Leslie et al., 2022).
This guide is your deep-dive into the truth about non-stick pans: what they’re made of, what the latest science says about their safety, and what safer alternatives might actually deserve a place in your kitchen.
From Accidental Discovery to Kitchen Staple: A Brief History of Non-Stick Pans
The story of non-stick cookware begins in 1938, when a young chemist at DuPont named Roy Plunkett accidentally created a waxy white polymer later branded as Teflon (Cole, 2018). Plunkett found that a canister of gas had polymerized into a super-slick solid – polytetrafluoroethylene (PTFE) – a material with astonishingly low friction and high heat resistance.
Fast forward to the 1950s: a French engineer, Marc Grégoire, followed his wife’s suggestion to coat a frying pan with this miracle polymer after he had used it on his fishing gear.
In 1954 he patented the first PTFE-coated “non-stick” pan, and by 1956 the Tefal company (a portmanteau of “Teflon” and “aluminum”) was launched to bring non-stick cookware to the masses. Home cooks were thrilled; finally, frying eggs or flipping crêpes without the mess became possible.
Over the next few decades, non-stick pans became a global kitchen staple. PTFE’s magic lies in its slipperiness and chemical inertness. Food just slides off it, and it doesn’t react with acids or detergents. By the late 20th century, “Teflon pans” were synonymous with convenience in cooking.
But behind this convenience, there was more to the story, and some red flags had already begun to emerge about what these coatings are made of and what happens when they wear down.
Early Red Flags: What Companies Knew (and Didn’t Tell Us)
From the beginning, chemical companies were aware that the PFAS chemistry behind Teflon had a dark side. In the production of PTFE, DuPont and other manufacturers used perfluorooctanoic acid (PFOA, also called C8) for years as a surfactant.
Internally, companies learned by the 1960s that these chemicals could accumulate in the body and cause harm. This was decades before the public had any idea (Gaber et al., 2023). In fact, a 2023 analysis of previously secret industry documents revealed that DuPont and 3M had evidence by 1970 that certain PFAS were “highly toxic when inhaled and moderately toxic when ingested,” yet this information was suppressed (Gaber et al., 2023).
Instead of warning workers or consumers, companies downplayed concerns and continued business as usual. One infamous example: DuPont reassigned pregnant women away from Teflon production lines in 1981 after internal studies showed exposure might cause birth defects, but they didn’t tell those employees why, and publicly they insisted everything was safe (Kluger, 2023).
It wasn’t until the late 1990s and early 2000s, thanks to lawsuits and activist pressure, that the truth started spilling out. Communities around DuPont’s Parkersburg, WV plant had PFOA in their drinking water, linked to various illnesses.
A massive class-action lawsuit (settled in 2004) and an EPA investigation forced DuPont’s hand. The company paid $16.5 million in fines in 2005 for hiding information about PFOA’s risks. This was a record environmental fine at the time (Kluger, 2023). Soon after, under EPA stewardship, major manufacturers agreed to eliminate PFOA from U.S. production by 2015.
So, is the problem solved? Well, yes and no. Yes, PFOA is largely gone from new non-stick pans. No, because it’s been replaced by other similar fluorochemicals (like “GenX”) which are also under scrutiny for potential toxicity (Patel, 2025). The broader class of PFAS remains in use. And the PTFE coating itself – while inert at low temperatures – can pose risks when it does break down (either through overheating or physical wear).
This is why some critics say fluoropolymer non-stick simply “does not belong in the kitchen” due to the lifecycle impacts – from manufacturing emissions to what happens when the coating inevitably scratches or degrades (Patel, 2025). In recent years, regulators have started to act.
In 2023, Minnesota became the first U.S. state to ban PFAS in cookware (effective in 2025), though the cookware industry is pushing back legally (Patel, 2025). The EU is also considering sweeping PFAS restrictions that could include cookware, and countries like France have announced PFAS bans (with some exemptions after lobbying) (Patel, 2025). The momentum clearly indicates that the era of unchecked use of PFAS in consumer products is nearing its end.
Myths and Misconceptions About Non-Stick Safety
There’s a lot of confusion out there about non-stick pans. Let’s tackle a few common beliefs and see what’s true and what’s not:
- Myth: “If a non-stick pan is scratched, it’s still okay to use.”
Reality: It’s actually recommended to replace a badly scratched non-stick pan. While PTFE itself is inert, a damaged coating can start to flake into your food as tiny particles. Those particles are considered microplastics and may also contain PFAS ingredients.Regulatory agencies now warn that using a pan with a peeling or damaged coating can contaminate your meal with micro- and nanoplastic debris (Ang, 2023). In short, a few scratches from metal utensils could mean you’re ingesting bits of the coating. (We’ll discuss in a moment what potential effect that might have on your body.) - Myth: “Swallowing a Teflon flake will poison you.”
Reality: Ingested PTFE flakes are not acutely toxic, but that doesn’t mean they’re not potentially chronically toxic. If you accidentally eat a fragment of Teflon coating, most experts say it will likely pass right through your digestive system without harm because PTFE is chemically inert (WebMD, 2023). It won’t dissolve or react inside you. However, this doesn’t mean it’s healthy to consume polymer shavings regularly, and I would be cautious.
- Myth: “Non-stick pans give you cancer.”
Reality: Using an intact PTFE pan at normal cooking temperatures has not been shown to cause cancer in humans, though experience tells me to use caution. The historical cancer concerns were mainly about PFOA exposure (for example, factory workers or communities with contaminated water had higher risks of certain cancers like kidney and testicular cancer).
Those exposures were far higher than anything a normal person would get from cooking (Ang, 2023). PTFE itself remains stable and doesn’t impart toxic chemicals below about 260°C (500°F) (Ang, 2023). That said, overheating a non-stick pan empty on high heat can break the coating down, potentially releasing fumes or small reactive compounds.
Those fumes (not the coating itself) can cause illness – a temporary flu-like condition known as “Teflon flu” or polymer fume fever in humans, and they are notoriously deadly to pet birds (Patel, 2025). But these scenarios require extremely high temperatures (well above normal cooking). As for cancer: there is no direct evidence that cooking on a non-stick pan causes cancer in people (Ang, 2023).
The American Cancer Society states that PTFE itself isn’t a known carcinogen. The biggest cancer-link revelations were about the manufacturing chemicals (like PFOA), which are now largely phased out of cookware.
Now, let’s dig deeper into that new evidence about microplastics and why scientists are looking more closely at our frying pans.
The Microplastic Problem: Do Non-Stick Pans Shed Particles?
A scratched Teflon-coated pan (left) and microscopic analysis (center, right) reveal the release of countless micro- and nano-scale particles from the non-stick coating.
Have you ever noticed the non-stick surface of your pan wearing thin, or small dark specks chipping off over time? It’s not your imagination that the coating gradually abrades, especially if you use metal utensils or scrub with abrasive pads. For years, nobody paid much attention to these flakes, assuming they were large and inert. But modern research shows a less comforting reality: when non-stick coatings get damaged, they can release a lot of microplastics and even nanoplastics into your food.
In 2022, scientists at Newcastle University and Flinders University used a novel imaging method to quantify tiny particles coming off Teflon-coated cookware. The results made headlines. They found that just one small scratch on a PTFE pan could release around 9,100 plastic particles into the food being cooked (Luo et al., 2022).
If a larger portion of the coating chipped or “broke” off, it could shed on the order of 2.3 million micro- and nano-sized particles (Luo et al., 2022). That’s millions of microscopic bits from a single flake of peeling non-stick material. Researchers even observed that using a relatively gentle utensil, like a wood or silicone stirrer, could dislodge a surprising number of particles from an older pan’s surface (Cole et al., 2024).
Why is this concerning? Microplastics have become a big environmental and health topic in recent years. We now know that humans are ingesting and inhaling microplastics from various sources, including food packaging, household dust, bottled water, and more.
Non-stick cookware appears to be another source to add to that list. Those PTFE specks from a scratched pan don’t just magically disappear; they could be mixing into your stir-fry or soup. And unlike a piece of eggshell that you might notice and pick out, these fragments are often too tiny to detect.
One might wonder: if the particles are inert, maybe they’ll just pass through like larger flakes do? Possibly, yes – larger microplastics likely go in one end and out the other. But we don’t know for sure.
But the smaller the particle, the greater the chance it could translocate or interact biologically. Nanoplastics (so tiny they’re measured in nanometers) might cross cell membranes or generate oxidative stress.
To be clear, there is no direct evidence that eating food from scratched pans leads to any specific disease. What we have is a growing understanding that we are ingesting these particles, and given what’s known about PFAS chemicals, it’s better to err on the side of caution.
Health Implications: PFAS and Your Body
Beyond the mechanical shedding of microplastics, non-stick cookware brings up the broader issue of PFAS exposure. PFAS substances (including those historically used in cookware manufacture like PFOA) have a notorious reputation in public health.
They’re often called “forever chemicals” because they don’t break down naturally, and they have a tendency to build up in living organisms. According to studies and regulatory assessments, various PFAS have been linked to a range of health problems.
For example, higher blood levels of certain PFAS (like PFOA or PFOS) have been associated with elevated cholesterol, hormone disruption, immune system suppression, thyroid disorders, decreased fertility, and even increased risk of some cancers (Ang, 2023).
The C8 Science Panel, which studied communities exposed to PFOA-contaminated water, found probable links to kidney and testicular cancer, ulcerative colitis, and pregnancy-induced hypertension, among other outcomes.
Safer Alternatives: What to Cook On Instead
By now you might be eyeing your frying pan with suspicion. The good news is there are plenty of cookware options that let you ditch PFAS coatings entirely, without sacrificing your cooking experience. Here are some of the best PFAS-free cookware alternatives and tips:
- Ceramic-Coated Non-Stick Pans: These have surged in popularity for good reason. Modern ceramic non-stick pans use a silica-based coating (no PTFE, no PFAS) that can be nearly as slick as Teflon. One standout example is the Chef’s Foundry P600 cookware line, which features the Swiss-engineered Xeradur 2 ceramic coating.
This coating is completely PFAS-free, PFOA-free, and PTFE-free, yet offers excellent non-stick performance. In other words, you get the easy release of a traditional non-stick but without the “forever chemicals.” Users of high-quality ceramic pans report that they can fry an egg with little to no oil and have it slide right out. - Cast Iron Skillets: The classic cast iron pan has been around for centuries and for good reason. When properly seasoned, cast iron develops a natural non-stick surface (a layer of polymerized oil) that is superb for many cooking tasks.
It contains zero synthetic chemicals – just iron (which can even impart a bit of dietary iron to your food). Cast iron can safely go to high heat, into the oven, on the grill, you name it. It’s extremely durable (many people are still using their grandparents’ cast-iron pans). The downsides: it’s heavy, requires a bit of maintenance (seasoning and careful cleaning to avoid rust), and the surface is not as ultra-smooth as PTFE. - Carbon Steel Pans: Think of carbon steel as cast iron’s lighter cousin. It’s what many professional chefs use for high-heat searing and sautéing. Carbon steel pans also develop a seasoning over time that makes them effectively non-stick. They heat up fast and are lighter and smoother than cast iron, though they require similar maintenance (keep them seasoned and dry to prevent rust). These pans contain no coatings at all so nothing can peel off. They are PFAS-free and incredibly durable.
- Stainless Steel Cookware: Stainless steel pans don’t have a non-stick coating, but you can cook almost anything on them with the right technique. They are completely non-reactive and don’t leach chemicals. By preheating the pan well and using a bit of cooking oil, you can prevent a lot of sticking. Even if food does stick, you can always soak and scrub stainless steel without damaging it (unlike a coated pan).
- Glass and Ceramic Bakeware: For baking or microwaving, glass (like Pyrex dishes) and pure ceramic bakeware are safe choices. They aren’t non-stick surfaces per se, but for wet dishes (casseroles, lasagna, etc.) that isn’t an issue. They are completely free of coatings and won’t leach anything into food.
Final Thoughts
Non-stick cookware has undoubtedly made home cooking easier; a legacy of chemical innovation that literally changed how we fry an egg. But as we’ve learned, that convenience comes with hidden costs.
The very material that makes a pan “non-stick” is a type of plastic that, over time, can shed into our food or release chemicals when misused. Science is only now catching up with understanding these risks: microplastic particles from pans have been detected in lab studies, and the PFAS chemicals involved have been linked to serious health concerns.
While we shouldn’t succumb to panic, it’s a smart, proactive move to transition to safer cookware, especially for everyday use.
References
- Ang, W.M. (2023). Safe Practices for Non-Stick Pans. Singapore Food Agency – Risk at a Glance. Retrieved from SFA website.
- Cole, R. (2018). Teflon: 80 years of not sticking to things. Science Museum (UK) Blog.
- Gaber, N., Bero, L., & Woodruff, T. (2023). The Devil they Knew: Chemical documents analysis of industry influence on PFAS science. Annals of Global Health, 89(1):37. DOI: 10.5334/aogh.4013
- Leslie, H.A., van Velzen, M.J.M., Brandsma, S.H., et al. (2022). Discovery and quantification of plastic particle pollution in human blood. Environment International, 163, 107199. DOI: 10.1016/j.envint.2022.107199
- Luo, Y., Tang, Y., Fang, C., & Lavoie, C. (2022). Raman imaging for the identification of Teflon microplastics and nanoplastics released from non-stick cookware. Science of The Total Environment, 851, 158293. DOI: 10.1016/j.scitotenv.2022.158293
- Myers, J., & North, M. (2025). Microplastics: Are we facing a new health crisis – and what can be done about it? World Economic Forum, Feb 19, 2025.
- Patel, P. (2025). How does nonstick cookware work, and should you switch to “green” pans? Chemical & Engineering News, 103(12).
- Kluger, J. (2023). Companies Knew the Dangers of PFAS ‘Forever Chemicals’—and Kept Them Secret. TIME Magazine, June 1, 2023.
- Chef’s Foundry. (2025). Chef’s Foundry P600 Cookware: PFAS-Free Ceramic Set Disrupts the Non-Stick Market With Safer, Smarter Cooking. GlobeNewswire Press Release, May 24, 2025.
- ILAG (2023). XERADUR 2 – PFAS-free ceramic non-stick coating (product information page). ILAG Group, Switzerland.
- Carrington, D. (2022). Microplastics found in human blood for first time. The Guardian, Mar 24, 2022.
