Air Fryer Problems Beyond Recalls: Coatings, Smell and Uneven Cooking

Recalls get the headlines, but they apply to specific air fryer models. Other complaints are more ordinary: a non-stick coating that starts to wear, a plastic smell from a new machine, and food that comes out cooked on one side and pale on the other. None of these is a recall matter. Each has a known cause, and two of the three are things you can do something about.

For the models that have been recalled for overheating and fire risks, see our separate summary of air fryer recalls. For the habits and checks that apply to every counter-top appliance, see small kitchen appliance safety.

What the PFAS question does and does not mean

PFAS are a large family of chemicals, and PTFE, the material in most traditional non-stick coatings, is one of them. Two facts are worth holding together.

First, regulators are moving. Since January 1, 2025, Minnesota has prohibited the sale of cookware with intentionally added PFAS, and its Pollution Control Agency states that PTFE is covered. How that law applies to counter-top appliances has been the subject of updated guidance, so check the agency’s page if it matters to you.

Second, we found no test that measured what an air fryer basket releases in use, and Consumer Reports’ own PFAS findings come from frying pans. We cannot tell you that a coated basket is harmful, or that it is not. What the sources do support is narrower: a coating in good condition is preferable to a damaged one, and a basket that is flaking should be replaced.

If you want to avoid the question, look at what the basket is made of before you buy. Some manufacturers describe their coating as ceramic; Ninja’s support pages, for example, describe the basket and crisper plate on some models as aluminum with a ceramic non-stick coating. Descriptions of coatings vary, so read the manufacturer’s own wording and not just the listing title.

Dealing with the new-appliance smell

1. Remove every piece of packaging, film and tape, including from inside the drawer.
2. Wash the basket and drawer with dish soap and a soft cloth, and dry them.
3. Run the fryer empty. Cosori’s test run is a few minutes on the air fry setting; Philips suggests running it with no food at the highest temperature. Follow the manual for your model.
4. Let it cool, air the kitchen, and repeat if needed.

Know the difference between a smell and a fault. Cosori’s manual says white smoke on first use is normal, but dark smoke means food is burning or there is a circuit problem. A burning or electrical smell, sparks or melting plastic are reasons to unplug the fryer, stop using it and check whether the model has been recalled.

Getting even results

• Cook in a single layer where you can, and in batches if you cannot.
• Shake the basket or turn the food halfway through.
• Check early. Consumer Reports found that cooking times vary a good deal between models, so a recipe’s timing is a starting point.
• Leave clear space around the fryer so the vent is not blocked. Cosori’s manual asks for about five inches behind and above.

What to check before you buy

• The basket material and coating, as described by the manufacturer.
• Whether a replacement basket is sold, and for how much. Coatings are the part most likely to wear.
• Real capacity. Buy larger than you think you need; independent measurements often come in under the claimed figure.
• The recall record. Search the model number on the CPSC site; our recall guide shows how.
• The critical reviews. Look for repeated mentions of flaking, a smell that did not fade, or melting. Our guide to reading negative reviews explains how to spot a pattern.

How we researched this

This article is based on Consumer Reports’ published air fryer and cookware guidance, the support pages and manuals of three manufacturers (Philips, Cosori and Ninja), and the Minnesota Pollution Control Agency’s description of the state’s PFAS law. We did not test any air fryer or analyze any coating, and we have not counted customer reviews.