This paper reviews the current trends in replacing commonly used plasticizers in poly(vinyl chloride), PVC, formulations by new compounds with reduced migration, leading to the enhancement in mechanical properties and better plasticizing efficiency. Novel plasticizers have been divided into three groups depending on the replacement strategy, i.e., total replacement, partial replacement, and internal plasticizers. Chemical and physical properties of PVC formulations containing a wide range of plasticizers have been compared, allowing observance of the improvements in polymer performance in comparison to PVC plasticized with conventionally applied bis(2-ethylhexyl) phthalate, di-n-octyl phthalate, bis(2-ethylhexyl) terephthalate and di-n-octyl terephthalate. Among a variety of newly developed plasticizers, we have indicated those presenting excellent migration resistance and advantageous mechanical properties, as well as those derived from natural sources. A separate chapter has been dedicated to the description of a synergistic effect of a mixture of two plasticizers, primary and secondary, that benefits in migration suppression when secondary plasticizer is added to PVC blend.

Low solubility of terephthalic acid in common solvents makes its industrial production very difficult and not environmentally benign. Ionic liquids are known for their extraordinary solvent properties, with capability to dissolve a wide variety of materials, from common solvents to cellulose, opening new possibilities to find more suitable solvents for terephthalic acid. This work presents studies on the solubility of terephthalic acid in ionic liquids, and demonstrates that terephthalic acid is soluble in ionic liquids, such as 1-ethyl-3-methylimidazolium diethylphosphate, 1-butyl-3-methylimidazolium acetate, and dialkylimidazolium chlorides up to four times higher than in DMSO. Additionally, the temperature effect and correlation of ionic liquid structure with solubility efficiency are discussed.

Alkyl lactates are produced from lactic acid via esterification, and are used in the production of plastics, paints, solvents and detergents. In the pursuit of an inexpensive, industry-suitable catalyst for this reaction, the application of protic ionic liquids based on nitrogen base and sulphuric acid is proposed. The ionic liquid was synthesised via a simple reaction of triethylamine and a threefold molar excess of sulphuric acid. Water was added to remove the heat of the reaction. Next, the reaction conditions for the model esterification of 2-ethylhexanol with lactic acid without additional solvent were optimised. Exceptionally mild conditions, i.e., a twofold molar excess of alcohol to lactic acid with the addition of an ionic liquid in a catalytic amount (15 mol%) at 60 °C, resulted in high yields of ethyl and 2-ethylhexyl lactates (96–97%). The driving force of this reaction is the production of a biphasic system with immiscible ester during the reaction. This phenomenon makes it possible to overcome the reaction equilibrium. Using an inexpensive ionic liquid, which could be recycled up to five times without diminution in conversion or selectivity, leads to both a greener and a more economically-viable process.

Inexpensive Brønsted acidic ionic liquids based on trimethylamine and sulfuric acid are proposed as both solvents and catalysts in the synthesis of alternative plasticizer bis(2-ethylhexyl) terephthalate, which has a broad spectrum of applications in plasticization processes. The utilization of 50 mol % of Brønsted ionic liquid led to the full conversion of terephthalic acid after 8 h of reaction at 120 °C. Additionally, a 100% selectivity of bis(2-ethylhexyl) terephthalate was obtained. The advantage of the presented reaction system is based on the formation of a biphasic system during the reaction. The bottom phase consists of an ionic liquid and water, and the upper phase is created by the ester and unreacted alcohol. This phenomenon helps overcome the equilibrium of the reaction and drives it towards a high yield of product. The presented new approach is proposed as a safe, cost-effective, and alternative method to conventional processes with organometallic compounds that, in turn, leads to greener and a more economically viable technology.

As a result of strict regulations of phthalate plasticizers, alternative non-phthalate forms are desired and increasingly used. This work presents a synthetic method for alternative plasticizers (dialkyl succinates and adipates) via esterification of succinic and adipic acid with alcohols: butan-1-ol and 2-ethylhexan-1-ol. Ionic liquids were synthesized by the reaction of triethylamine with over-equimolar (1:2.7) amounts of sulfuric(VI) acid, which were used as an acidic catalyst and solvent. The two-phase liquid–liquid system was formed during the reaction due to immiscibility of the esters with the ionic liquid. This phenomenon is a driving force of this process, shifting the equilibrium toward the product formation. As a result, dialkyl succinates and adipates were obtained in high yields (99%) and selectivities (>99%), under mild reaction conditions at 70–80 °C and using a 4:1 molar ratio of alcohol to acid and 15 mol% of catalyst. The catalyst was recycled 10 times without any loss of activity. This alternative method is highly competitive: it involves a simple procedure for product isolation as well as a high yield and purity of the resulting esters. These advantages make this method sustainable and promising for industrial applications.