Popcorn Lung: What is It, and What Makes You at Risk of Having It?

June 11 2025, by Tatianna Gerard, 10 min reading time

Have you noticed how vaping has become such a common sight these days? You’re definitely not alone. In fact, according to the National Drug Strategy Household Survey 2022–2023, about 1 in 5 people aged 14 and over in Australia—nearly 20%—have tried using e-cigarettes at least once. For many young adults, especially those aged 18–24, it’s even more common—21% of them are currently using e-cigarettes.

What’s interesting is that curiosity seems to be the main reason why people start. That same survey found that 39% of people said they first tried vaping simply because they wanted to see what it was like.

Since 2019, the number of people who’ve tried vaping has nearly doubled. But with all this curiosity and convenience, there’s something important that doesn’t always get enough attention: the potential risks that come with vaping—especially to your lungs.

One condition that’s been gaining more attention recently is called popcorn lung, or bronchiolitis obliterans. It might sound like something you’d hear about in a factory, and that’s partly true—it was first discovered in workers exposed to certain harmful chemicals used in popcorn flavouring. But what many people don’t realise is that these same chemicals, like diacetyl, can also be found in some e-cigarette liquids.

Popcorn lung is rare, but it’s serious and, unfortunately, it’s permanent. Maybe you’ve come across the term before, or maybe this is the first time you’re hearing about it. Either way, it’s worth understanding what it is, how it happens, and what early warning signs to watch out for.

Causes of popcorn lung

So, what exactly causes popcorn lung? It all comes down to exposure to certain harmful chemicals—most notably, a substance called diacetyl.

Diacetyl is a flavouring agent that gives foods a rich, buttery taste. It was widely used in the past to create that delicious buttery flavour in microwave popcorn, which is actually how the condition got its name. Unfortunately, when inhaled in large amounts—like in factories where workers were breathing in diacetyl-laden vapours—it can damage the smallest airways in the lungs, leading to scarring and narrowing of these passages. This scarring is what’s known as bronchiolitis obliterans, or popcorn lung.

The link between diacetyl and lung damage first came to light when workers in popcorn factories started showing signs of serious, irreversible breathing problems. Scientists eventually traced it back to the diacetyl they were breathing in every day. While this was a wake-up call for the food industry, diacetyl hasn’t entirely disappeared.

Beyond diacetyl - Other risks to lung health

In fact, it has found its way into some flavoured e-cigarette liquids. When you vape these products, you’re potentially inhaling diacetyl directly into your lungs. Over time, this exposure can cause the same kind of damage that factory workers experienced—only now, it’s not confined to a factory setting. That’s why there’s growing concern about vaping, especially flavoured vapes that might contain this harmful chemical.

But it’s not just diacetyl. Other toxic substances, like certain volatile organic compounds (VOCs) and even some heavy metals, can also be present in e-cigarette vapours (from various sources, including the e-liquid itself, the e-cigarette device, and even through secondary reactions), and in industrial environments. People who work in industries that produce food flavourings, coffee roasting, or other similar processes can be exposed to these chemicals too. And of course, smoking cigarettes also exposes your lungs to a cocktail of harmful substances that can cause long-term damage.

Symptoms of popcorn lung

Popcorn lung can be tricky to spot in the early stages because its symptoms often look a lot like those of other, more common lung conditions. But knowing what to watch for is the first step in getting help early—and potentially slowing down the progression of the disease.

Here are some common symptoms to keep an eye on:

A persistent, dry cough that doesn’t seem to go away
Shortness of breath, especially when you’re active
Wheezing or a whistling sound when you breathe
Feeling unusually tired or fatigued
A feeling of tightness or discomfort in the chest

Because these symptoms overlap with other respiratory conditions, like asthma, COPD or chronic bronchitis, popcorn lung can be misdiagnosed. If you’re experiencing these symptoms and you know you’ve been exposed to things like vaping, certain chemicals at work, or even heavy cigarette smoke, it’s important to mention that to your doctor. Letting them know about any possible exposure to diacetyl or other harmful chemicals can help them piece together what might be going on.

It’s also important to know that popcorn lung is unfortunately irreversible. Once the smallest airways in your lungs have been scarred, the damage can’t be undone. That’s why catching these symptoms early—and avoiding further exposure to harmful chemicals—is so important.

Preventing popcorn lung

The best way to protect yourself from popcorn lung is to avoid the harmful chemicals that can trigger it in the first place. Here’s how you can reduce your risk:

Avoid vaping, especially flavoured e-cigarettes

Some of these products contain diacetyl and other harmful chemicals that can damage your lungs. If you’re thinking about quitting, there are many resources and support services available in Australia to help you stop for good.

Take care if you work in environments with potential exposure

Jobs in food flavouring factories, coffee roasting, or other industrial settings might involve inhaling chemicals like diacetyl. These substances can be particularly dangerous because the particles are incredibly small—diacetyl vapours can be less than 1 micron in size, which means they can easily reach the deepest parts of your lungs when you breathe them in.

That’s why using the right protective equipment is so important. For example, the Australian P2 mask brand, AMD, has a Particle Filtration Efficiency (PFE) of ≥99.66%, which means it can filter out almost all fine airborne particles, including these tiny diacetyl vapours. Wearing a properly fitted P2 or N95 respirator like AMD’s can make a real difference in limiting your exposure to these harmful chemicals. Of course, improving ventilation and following your workplace’s safety measures are also key steps in protecting your lungs from damage.

Shop AMD P2 Masks with earloops and headband options at Aussie Pharma Direct.

Stop smoking and steer clear of secondhand smoke

Smoking already puts a heavy burden on your lungs, and combining that with exposure to other harmful chemicals can make things even worse.

Stay proactive about your lung health

If you work in a risky environment or you vape, talk to your doctor about regular lung health check-ups. They can help catch any early warning signs and advise you on how to keep your lungs as healthy as possible.

At the end of the day, the best protection comes from staying informed and making choices that put your long-term health first. Popcorn lung might be rare, but taking a few simple steps can go a long way in keeping your lungs healthy and strong.

How AirPhysio supports and help you manage respiratory conditions

Even though popcorn lung causes permanent damage to the smallest airways, that doesn’t mean you’re powerless to support your lungs. Managing your respiratory health is crucial, especially if you’ve been exposed to harmful chemicals or are already dealing with breathing difficulties.

One tool that can be helpful is AirPhysio, a simple, drug-free device that uses oscillatory positive expiratory pressure (OPEP) therapy to help improve your lung function. It works by creating vibrations in your airways as you breathe out through it, which helps loosen mucus and expand your airways. This makes it easier to clear out built-up mucus and improve your lung capacity over time—something that can be particularly helpful if your lungs are already compromised.

It’s important to know that AirPhysio is not a treatment or a cure for popcorn lung, or any other lung condition. Instead, it’s designed to be a supportive tool that can help you manage your symptoms and breathe a little easier. And because AirPhysio is drug-free, doesn’t need a prescription, and doesn’t operate on batteries, it’s a safe and convenient option for many people.

AirPhysio also comes in four variations to suit different needs:

For Low Lung Capacity: Comes in two resistance settings. Ideal for elderly users or those with more severe breathing difficulties.
For Average Lung Capacity: Suitable for most adults and teenagers to maintain or improve their lung capacity.
Sports: Designed with higher resistance for active people or athletes who want to improve their lung performance.
For Children: A gentler version, with lower resistance, specifically designed for kids.