Brigit Fassbender, Budenheim noted that flame retardants (FRs) represent around one third of polymer additives, and pointed to market tendencies towards FRs with lower smoke emissions and positive toxicity and environmental profiles. Intumescent PIN FRs act by forming a barrier which prevents oxygen entering into contact with flammable gases released from polymers, insulates against heat and also reduces emission of smoke. They do not generate black smoke by pyrolysis in the gas phase of combustion. However, challenges are to prevent migration to the polymer surface over product life (blooming: “dashboard” test), to avoid water uptake and to minimise loss of polymer mechanical properties resulting from FR loading. Budenheim has developed improved formulations of the recognised and effective PIN FR, ammonium polyphosphate, using a new coating which does not contain formaldehydes. Such coated APP based systems improve processing, prevents migration and water uptake and improves thermal stability. UL94-V0 (1.6 mm) is achieved in polyolefins and mechanical performance is maintained (tensile modulus and strength) or improved (elongation at break) compared to standard intumescent FR