Top 3 Industrial Additives for Phenol-Formaldehyde Resins
Phenol-formaldehyde (PF) resins are among the most established synthetic polymers in industry. For over a century, they’ve been valued for their mechanical strength, heat resistance, and chemical durability — underpinning products from laminates and adhesives to coatings and insulation materials.
But the PF market is evolving. Sustainability targets, tightening regulations on formaldehyde, and growing demand for functional materials are driving formulators and manufacturers to rethink what PF resins can be.
Today, three industrial additives are leading the way in defining the next generation of PF systems: lignin, 5-hydroxymethylfurfural (5-HMF), and carbon nanomaterials. Together, they combine greener chemistry with advanced performance — allowing PF resins to remain relevant in a changing industrial landscape. And here’s how…
1. Lignin – The Renewable Substitute for Phenol
Lignin is one of the most abundant natural polymers on Earth, found in wood and plant cell walls and readily available for manufacturers as a by-product of the pulp and paper industry. As an industrial feedstock, lignin offers a renewable and cost-effective way to partially replace petroleum-derived phenol in PF resin synthesis.
By substituting up to half of the phenol content, the use of lignin as an industrial feedstock can significantly reduce the reliance on fossil-based raw materials.
In addition to lowering material costs, the aromatic structure of lignin also contributes to greater thermal stability, allowing lignin-modified PF resins to perform reliably under elevated temperatures.
In some cases, PF performance has even been improved through the inclusion of lignin. For instance, a 2025 study published in the International Journal of Biological Macromolecules found that, “replacing 10-30 % of phenol with lignin improves resin properties, including increased viscosity, enhanced reactivity, greater cohesion strength, and a higher degree of methylene linkages, which contribute to stronger adhesive bonds. In addition, laminated veneer lumber (LVL) bonded with lignin-modified PRF resins exhibited superior adhesion performance and lower formaldehyde emissions compared to conventional PRF resins.”
That said, a further study noted weakened adhesive properties in the manufacture of chipboard when lignin was used as input. The report, conducted by researchers from the University of Zagreb explaining that, “unmodified kraft lignin was used as a substitute in a commercial phenol-formaldehyde resin, with the substitution rate being 10 %.” Testing of the particleboard finding that, “the addition of lignin to the PF resin negatively affected these properties, while particleboards bonded with lignin-modified PF resin met the requirements of the standard for lower-class particleboards.”
Challenges still remain before lignin can be used as an additive to PF, as product quality can vary greatly by source, and its reactivity is generally lower than phenol’s. This can affect crosslinking density and colour uniformity, although modern modification techniques (e.g., phenolation or methylolation) can mitigate these issues.
That being said, incorporating lignin into PF enables manufacturers to offer ‘low-carbon’ products without having to re-engineer entire production lines — a significant strategic advantage under emerging ESG and green procurement frameworks.
2. 5-HMF – The Safer Alternative to Formaldehyde
As well as lignin, 5-Hydroxymethylfurfural (5-HMF) is also attracting a great deal of attention.
This is because, not only is 5-Hydroxymethylfurfural (5-HMF) a non-toxic alternative, but as a bio-based compound derived from sugars such as fructose and cellulose, it is also completely sustainable while still offering similar chemical functionality.
Additionally, 5-HMF is gaining popularity due to formaldehyde’s classification as a Category 1B carcinogen under REACH legislation, suggesting it as a safer alternative.
Although this comes at a higher price, with markets still offering 5-HMF as a premium additive due to limited production scale driving up costs. It also alters curing kinetics — requiring formulation adjustments to achieve optimal hardness and stability.
Though currently niche, 5-HMF is likely to play a growing role in low-emission adhesives, coatings, and composite binders. For manufacturers serving electronics, automotive, or interior applications where air-quality standards are strict, early adoption may provide a regulatory and marketing advantage.
3. Carbon Nanomaterials – Adding Conductivity and Strength
While lignin and 5-HMF make PF resins more sustainable, carbon nanomaterials provide unique-selling points and properties.
Through the smart application of carbon nanomaterials, PF-based systems can expand into high-value markets — from conductive surfaces and antistatic coatings to hybrid composites. This creates a clear route for differentiation in otherwise mature adhesive and resin markets.
Specifically, the inclusion of carbon nanomaterials into phenol-formaldehyde resins can provide the following functional advantages:
· Electrical conductivity: Enables antistatic and dissipative surfaces, crucial for electronics assembly lines, clean rooms, and ESD protection zones.
· Structural reinforcement: Improves tensile and flexural strength, abrasion resistance, and dimensional stability.
· Thermal durability: Enhances heat conductivity and performance under fluctuating temperatures.
As in other manufacturing sectors, nanotechnology is increasingly being used to improve products, and for PF producers, this includes adoption in coatings, workbenches, storage systems, and counter surfaces.
Today, off-shelf-products can be obtained as a dependable source of carbon nanomaterial additives. Products such as NANO AC FF-70 (a concentrate consisting of a mixture of phenol formaldehyde resin and 0,05 – 4 wt.% of carbon nanomaterials) ensures that nanoscale carbon structures are uniformly dispersed making it is possible to achieve controlled surface resistivity without compromising the mechanical integrity of the resin film.
This product is supplied by NANO CHEMI GROUP, a Prague-based supplier of nanotechnology additives and industrial ingredients. To find out more about the company (which sponsors this website) please contact info@nanochemigroup.cz or visit NANO CHEMI GROUP.
This list of potential industrial additives for phenol-formaldehyde resins is not exhaustive. Instead, it is intended to highlight the value which distinct feedstocks can bring to manufacturers. In practice, many formulators are experimenting with hybrid approaches — combining bio-based and nanomodified elements to balance sustainability, cost, and function.
Phenol-formaldehyde resins remain a cornerstone of industrial chemistry. But as markets change, the incorporation of industrial additives such as lignin, 5-HMF, and carbon nanomaterials is enabling manufacturers to reduce environmental impact, comply with increasingly strict regulations, and create high-value products that differentiate themselves for increasingly demanding customers.
Looking ahead, the most successful PF formulations are likely to be those that integrate multiple additive strategies, combining renewable feedstocks with advanced functional materials to deliver resins that are not only stronger and more durable but also smarter and more environmentally responsible.
Photo credit: Wikimedia, NANO CHEMI GROUP, Wikimedia, & Wirestock on Freepik
