Greenpan: Toxic-Free Cookware?

GreenPan is a cookware brand available for purchase online and through national retailers like Target and Bed, Bath & Beyond. The company established a reputation for selling so-called eco-friendly, non-stick cookware that it claims is better for you than competing products.

The original GreenPan cookware uses a patented Thermolon™ ceramic non-stick coating that the company has at one time or another advertised as completely toxin-free, healthy, and free of PFOA, PFAS, lead, and cadmium. However, the company has come under scrutiny for these claims, with accusations of misrepresentation and greenwashing.

In 2012, for instance, GreenPan took heat from the National Advertising Division for making untrue claims within its advertisements. After the NAD’s critiques, GreenPan changed the wording within its ad campaigns. The new wording, while technically different, could be seen to be just as misleading as before, though.

Individual consumers have also hit back at Greenpan for its marketing tactics, as exemplified by a lawsuit brought in 2019. A 2019 class-action lawsuit (Saldivar vs. The Cookware Company (USA) LLC) brought many of the concerns about GreenPan into the courtroom. The lawsuit was brought by a consumer, Anna Saldivar, who claimed she was duped by GreenPan’s advertising to spend more money on a pan she was promised would be healthier and more environmentally friendly.

The lawsuit breaks down GreenPan’s claims to show how the brand overstates the health and environmental advantages of its pans. According to the 2019 lawsuit, GreenPan’s Thermolon™ coating contains several toxins, including:

- Silane – a colorless, flammable gas that is toxic to breathe in and known for irritating the skin, eyes, and mucous membranes

- Aluminum oxide – exposure can lead to lung damage

- Tetraethoxysilane– respiratory and skin irritation

- Methyltrimethoxysilane – serious eye, skin, and respiratory irritation

- Potassium titanate – harmful if inhaled; potential carcinogen

However, we don't know for sure that GreenPan cookware contains or contained these chemicals, given that the lawsuit was dismissed.

GreenPan's Thermolon coating is made by a Sol-Gel process that results in forming a coating layer on the surface of the pan

The Thermolon coating on GreenPan products is made using a Sol-Gel process, which involves a colloidal suspension of hydrolyzed metal alkoxide particles in an organic solvent. This is applied to the pan using a conventional wet application technique, such as spraying, and then thermally cured at a temperature below 500°C.

The Thermolon coating is made by spraying a solution onto the surface of the pan, which then hardens in the oven. The solution is made from a derivative of sand, and no glue or additives are needed. The process emits 60% less CO2 than the production of traditional non-stick PTFE pans.

The Thermolon coating is heat-resistant up to 450°C and, unlike traditional non-stick pans, will not blister or release toxic fumes if overheated. It is also a great heat conductor, meaning you can cook at a lower heat setting and save energy. The coating allows you to use less oil or butter, and food releases easily, making cleaning simple.

The Thermolon coating is made from Silicon Dioxide (SiO2), which is the same composition as glass or sand. There are also some additional materials, such as pigments, which give the colour.

The coating layer mainly consists of silica (aka sand) but not only

The coating layer of GreenPan products mainly consists of silica (aka sand) but not only. The coating is made by a Sol-Gel process that results in forming a coating layer on the surface of the pan. This layer comprises mainly Silicon Dioxide (SiO2), which is the same composition as glass (or sand). There are some additional materials such as pigments that give the colour. All the materials in the coating are 100% safe for use in food contact coatings.

The Thermolon coating is made by a Sol-Gel process. This coating layer mainly consists of silica (aka sand) but not only. It may have additional materials, such as pigments. After being thermally cured, it acquires a durable inorganic polymer coating, whose composition is unknown. The Thermolon cooking surface can be further provided with a polytetrafluoroethylene (PTFE) coating.

According to the available GreenPan Thermolon coating test reports, provided before December 2021 (as of December 2021, they no longer disclose their test reports), both grey original and black diamond coatings were tested for a wide range of chemicals. The latter were found undetectable, except aluminum in one of the grey original coating reports. To clarify, “undetectable” means only that there are no findings over a certain reporting limit.

The Thermolon coating is made from inorganic ingredients, meaning it is safe to use in contact with all foods, and can be safely heated to 450°C/850°F and will not emit toxic fumes when overheated. Thermolon™ was tested by third-party labs and is certified safe according to USA Food & Drug Administration, German LFGB, Swiss government, and KTR standards.

It may have additional materials, such as pigments

The Thermolon coating is made by a Sol-Gel process that results in a coating layer on the surface of the pan. This layer mainly comprises Silicon Dioxide (SiO2), which is the same composition as glass (or sand). However, it may have additional materials such as pigments that give the pan its colour.

The Sol-Gel process involves the transformation of sand-derived raw materials into a sprayable solution. The liquid part of this solution is mainly water. After spraying onto the pans, the coating is then cured in an oven at a relatively low temperature.

The Sol-Gel process is summarised in the following excerpt:

> "The Thermolon coating is made by a Sol-Gel process that results in forming a coating layer on the surface of the pan. This layer comprises mainly Silicon Dioxide (SiO2), which is the same composition as glass (or sand). There are some additional materials such as pigments that give the colour. All the materials in Thermolon are 100% safe for use in food contact coatings."

The Sol-Gel process is further described as follows:

> "The Sol-Gel coating composition includes a colloidal suspension of hydrolyzed metal alkoxide particles in an organic solvent, which is applied to bare metal such as aluminium and its alloys or to porcelain enamelled metals or other substrates using a conventional wet application technique such as spraying. The sol-gel coating composition is then thermally cured at a temperature below about 500° C."

After being thermally cured, it acquires a durable inorganic polymer coating, whose composition is unknown

The Thermolon coating used in GreenPan products is made using a Sol-Gel process, which results in a coating layer on the surface of the pan. This layer is composed mainly of silicon dioxide (SiO2), which is the same composition as glass or sand. However, there are some additional materials, such as pigments that give the coating its colour.

After the Sol-Gel process, the coating is thermally cured. This involves heating the coating to a high temperature, causing an irreversible chemical reaction where the polymer chains cross-link and form a rigid material. In the case of GreenPan products, this results in a durable inorganic polymer coating. However, the exact composition of this coating is unknown.

Thermal curing is a common process used in the manufacturing of composites and other materials. It is often used to harden precursor resins during the manufacturing process, such as turning Bakelite, an early thermoset, into a hard material.

The exact process and composition of the Thermolon coating used in GreenPan products are not disclosed by the company, which has led to concerns about the safety of the product. While available test reports indicate that GreenPan products are safer than those coated with Teflon, the specific ingredients of the Thermolon coating are not listed, making it difficult to determine the safety of the product comprehensively.

The Thermolon cooking surface can be further provided with a polytetrafluoroethylene (PTFE) coating

However, PTFE has been associated with potential health risks. It can be manufactured using perfluorooctanoic acid (PFOA), which is considered a carcinogen and can cause flu-like symptoms, fertility issues, and thyroid disorders. While PFOA has been phased out of production in the US, it is still present in some PTFE products. Additionally, PTFE can degrade at high temperatures, releasing toxic gases and chemicals.

The potential health risks associated with PTFE have led to concerns about the safety of PTFE-coated cookware, including GreenPan products. While GreenPan claims that their Thermolon coating is PTFE-free, there have been lawsuits and consumer complaints about the presence of toxins and false advertising. Therefore, it is essential to consider the potential risks and conduct thorough research before using PTFE-coated cookware.

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