New Air Fryer Plastic Smell: Normal or a Warning Sign?

Why a new air fryer smells like plastic, the burn-off steps Philips and Instant give, how long it should last, and which smells mean unplug it now.

By Maksud · Published Sep 27, 2026

A light plastic or chemical smell from a new air fryer in its first few runs can be normal, per Cosori’s blog, and Philips says its plastic parts and PTFE-coated basket might release some smell during the first uses.

To reduce it, remove all packaging, wash the removable parts, then run the unit empty as your manual directs. Instant’s Vortex Plus 6qt guide specifies a test run at 400°F (205°C) for 18 minutes. A strong, worsening or electrical burning smell is not normal: unplug it and let it cool.

Why does a new air fryer smell like plastic?

Philips’ support page says the housing and inner drawer are plastic and the pan and basket are PTFE-coated. It says these parts might release some smell during the first uses because the appliance reaches up to 200°C. The page applies to specific Philips models (it lists NA555/00, NA330/00 and NA331/00, among others). Of the manufacturer sources we read, it gives the most specific explanation.

Cosori’s blog lists more causes of an air fryer burning plastic smell:

• Residue from manufacturing and first-time heating
• Packaging left inside: stickers, plastic film or foam inserts
• Dust from production and shipping
• Soap left on parts that weren’t rinsed well
• Blocked vents, or a unit pushed too close to a wall

These are manufacturer explanations. We found no independent lab study that identifies what the smell actually is.

First-use burn-off: what each manufacturer tells you to do

Each brand gives different instructions, so follow your own model’s manual. Here is what each source says.

The sources disagree on time. Instant’s test run is 18 minutes; Philips says to use the maximum timer. Cosori defers to each model’s manual.

One oddity: Instant’s guide calls 400°F and 18 minutes the “default” in the test-run steps, but its Air Fry program table lists the Air Fry default as 385°F and 15 minutes. Follow the test-run numbers as written. The model pages for the Instant Vortex Plus 6qt and the Cosori TurboBlaze collect what their manuals say.

Ninja isn’t in the table because we haven’t opened its owner’s guide for this page, and we won’t guess at its steps.

How to get rid of air fryer smell, step by step

These steps combine the Instant, Philips and Cosori instructions:

1. Take out all packaging, plastic film, foam inserts and packaging stickers, inside the basket and drawer too (Cosori). Instant says not to remove the safety warning stickers or the rating label.
2. Wash the basket and crisper plate in warm water with mild dish soap and a soft sponge, rinse off all soap and dry fully (Cosori; Instant and Philips give similar washing steps).
3. With the unit unplugged and cool, wipe the inside with a soft damp cloth (Cosori, Instant). Never submerge the base (Cosori).
4. Set it on a stable, level, heat-resistant surface away from combustible material, with your manual’s clearance: 5 in above and around the Instant; Cosori’s blog, citing Food & Wine, says 6 in from walls. Open a window or turn on a kitchen vent (Cosori).
5. Run the empty first-use cycle from your manual, and don’t leave it unattended (Cosori).
6. Let it cool and air out. If a smell remains, Cosori says to repeat the wash, dry and air-out, and run another empty cycle only if your manual allows it, letting the unit cool between cycles.

What not to use, per Cosori: steel wool, metal scrapers, abrasive powders, oven cleaner, bleach, or excessive vinegar or lemon juice, and don’t let foil cover the vents or heating element. Cosori says not to treat vinegar as a universal fix and to avoid heating lemon juice or acidic mixtures in the air fryer unless your manual says it is safe. Philips also warns against metal utensils and abrasive cleaning materials.

How long does the new air fryer smell last?

No manufacturer gives a firm count. Philips says the smell can happen during the first uses. Cosori says a mild odor often improves after the first few uses, depending on the model, materials, cleaning, ventilation and how long the unit was stored. Cosori’s blog also lists an odor during the first one to three heating cycles among signs that are usually normal.

If the smell is still strong after several proper cleaning and empty heating cycles, Cosori says to contact customer support rather than keep using the appliance. Use the checklist below.

Is air fryer smell dangerous? What the temperature data says

The published thresholds for PTFE fumes sit above the maximum temperatures these air fryers reach at normal settings.

This comparison is not a guarantee. The settings are the air fryers’ set temperatures, not measured coating temperatures, and none of these sources tested air fryers. The NCBI StatPearls chapter on polymer fume fever (an archived chapter) says the risk of vapor inhalation increases when PTFE-coated cookware is heated dry, which is what an empty burn-off does. A faulty element, a wiring fault or a fire is outside normal settings and outside this table.

Birds are the exception to take seriously. The Merck Veterinary Manual says PTFE gas poisoning occurs commonly in pet birds housed in or near kitchens, and that often the only clinical sign is acute death. It names certain nonstick cookware, not air fryers specifically. Moving birds well away from the kitchen during the burn-off is a cautious step.

As for food, no source we read says a first-use smell makes food unsafe, and none says it’s fine either. Finish the burn-off before you cook. For the broader PTFE and nonstick question, see are air fryers safe.

When does the smell mean stop using it?

Cosori’s blog says to unplug the air fryer and let it cool if you notice any of these, and to contact the manufacturer when in doubt:

• A strong or worsening burning or melting smell
• An electrical smell, sparks or unusual noises
• Smoke that is not clearly from food, including smoke with no food inside
• Visible warping, bubbling, discoloration or damaged parts
• A smell that continues after several proper cleaning and empty heating cycles
• Exterior areas that get unusually hot where you would not expect heat

Cosori also says not to try repairing electrical or heating components yourself.

A burning-plastic smell can have a real cause. On Feb 23, 2023, the CPSC announced a recall of about 2 million Cosori air fryers because a wire connection could overheat, posing fire and burn hazards. The CPSC says the firm, Atekcity, had received 205 reports of the air fryers catching fire, burning, melting, overheating and smoking, including 10 reports of minor, superficial burns and 23 reports of minor property damage. Recalled models include the CP158-AF, CP137-AF, CS158-AF, CO137-AF, CO158-AF, CP258-AF and the CAF-P581 and CAF-P581S series (plus color variants).

The CPSC says the model number is on the bottom label, and that owners of recalled units should stop using them immediately and contact Cosori for a replacement.

For any brand, search your model number at cpsc.gov, and contact the manufacturer if you’re unsure. If there are flames, follow how to put out a grease fire, and see what fire extinguisher to keep in a kitchen.

If the air fryer smell comes back weeks later

A smell that shows up after weeks of normal use is a different problem from break-in odor. For smoke while cooking, see why is my air fryer smoking. For grease and food buildup, see how to clean an air fryer. If the basket coating is flaking, see air fryer basket coating peeling.

More on air fryers

• Best air fryers: how the models we cover compare
• Instant Vortex Plus 6qt review
• Cosori TurboBlaze review
• Are air fryers safe?
• How we research
• Why a blender smells like burning