Circular Materials Fibre Pellets are produced from waste textiles, such as old clothes and production offcuts. The recycled fibres can be used as fibre reinforcement for plastics, such as polypropylene (PP), polyethylene (PE) and thermoplastic elastomer (TPE). The fibre-based composite is compatible with conventional plastic manufacturing processes, such as injection and compression moulding. It is suitable for a range of applications including products, packaging, point-of-sale (POS) and fashion accessories. For example, this tray in injection moulded using 25% fibre pellet and 75% recycled PP (rPP). Image Circular Materials.

SEFF hemp fibre for fashion and interiors, softened to resemble cotton. Image SEFF.

Syklo produce an innovative biocomposite consisting of post consumer recycled (PCR) polypropylene (rPP) combined with recycled paper. The paper is shredded and micro fibrillated (MFC) to create a highly functional additive that provides significant mechanical benefits. It can be injection moulded and provides a bio-based recycled alternative to conventional PP materials in packaging and product applications. Image Syklo.

LYB LyondelBasell CirculenRecover includes a range of products that include up to an impressive 100% post consumer recycled (PCR) content. The scrap is derived from plastic waste via a mechanical recycling process and is suitable for a range of applications in packaging, automotive and products. The range of colours possible depends on the source of scrap. Image LYB LyondelBasell.

Burpol offer a range of 100% recycled polypropylene (rPP) grades suitable for automotive interior parts. They are only available in black or dark colours. This ensure they can use mixed sources of scrap and so helps to manage the cost and impacts of the recycling processes.

Trexel MuCell microcellular foaming technology is used in combination with injection moulding to produce lightweight and durable shoe midsoles. It involves the injection of a supercritical fluid (SCF), typically nitrogen or carbon dioxide, into the molten plastic during the moulding process. This creates a microcellular foam structure within the plastic part, resulting in various benefits such as weight reduction, polymer reduction, reduced warpage and faster cycle times. The sole is moulded directly onto the fabric, finishing the shoe in a single step.

Tecnaro Arbofill materials are made from renewable raw materials and plastics. Aesthetic materials with interesting applications are the result of combining plastic and natural filler materials. Arbofill is suitable for injection moulding processes.

Hexpol produce a range of thermoplastic elastomers with recycled content (rTPE). This includes post industrial recycled (PIR) available in natural colours and suitable for consumer goods, sports equipment, footwear and automotive interior and exterior parts; post consumer recycled (PCR) material available in dark colours, from end of life vehicles and household waste, suitable for automotive exterior and technical parts, safety products and outdoor equipment; and maritime waste from old rope and fishnets available in available in black, blue, green and mint colours.

Boston Metal have developed an electrolytic process, molten oxide electrolysis (MOE), which enables the use of renewable energy sources in the production of steel. This direct approach eliminates several steps in the steelmaking process and does not require coke production, iron ore sintering and pelletising, blast furnace reduction or basic oxygen furnace refinement. Image BMW Group, who have invested in Boston Metal.

Continuous cast aluminium alloys from Raffmetal are produced from around 90% recycled scrap aluminium. The carbon footprint of their material is 2.18 kgCO2e/kg according to their life cycle analysis (LCA). This is significantly lower than the European average for aluminium, which is around 6.7 kgCO2e/kg. Image Raffmetal.

Uncaged Innovations are developing a leather alternative that is bio-based, animal-free and doesn’t require tanning like traditional leather. The process fuses structural proteins from grains with other bio-based elements to create fibril networks, replacing the animal collagen required for traditional leather. The company claims that the end product emits 95% less greenhouse gasses, 93% less water, and 72% less energy than traditional animal leather. Image Uncaged Innovations.

Sirmax Green Isofil recycled polypropylene (rPP), including standard and high performance grades modified with mineral fillers for added stiffness, suitable for automotive interiors, products and packaging. Certified flame retardant versions are available both halogenated and halogen-free. Image Sirmax.

Made of Air convert biomass waste streams (such as forestry offcuts and secondary agricultural materials), which have photosynthesised CO2, into a form of biochar through controlled pyrolysis. Burning materials without oxygen means the carbon cannot form CO2 and instead forms biochar. Using their technology the biochar is converted into a functional carbon-rich filler for plastic biocomposites. Biochar has been produced for centuries and is increasingly being used as a fertiliser as well as a way of sequestering carbon in the soil, because the carbon is locked in and it remains stable for hundreds of years. Image Made of Air.

Tritan Renew by Eastman uses chemically recycled polyester from sources like single use packaging to produce a new engineering copolyester with durable properties suitable for product enclosures, packaging, healthcare and food contact. Image Eastman.

Trexel MuCell microcellular foam injection technology is an innovative manufacturing process used to produce lightweight and cost-effective plastic parts. It involves the injection of a supercritical fluid (SCF), typically nitrogen or carbon dioxide, into the molten plastic during the moulding process. This creates a microcellular foam structure within the plastic part, resulting in various benefits such as weight reduction, polymer reduction, reduced warpage and faster cycle times. Image Trexel.

Borealis produce Bornewable bio-based polypropylene (bio-PP) using feedstocks derived from waste, such as used cooking oil. In this way, they do not compete with food. Up to around twice the price of standard PP, bio-PP offers a potentially carbon neutral solution in many applications. Image Borealis.

Campine recycled Polymers (CrP) produce a range of recycled polypropylene (rPP) grades from post production and post consumer recycled (PCR) waste. Image Campine recycled Polymers (CrP).

Fortum produce a range of recycled plastic materials under the trade name Circo including polypropylene (rPP), low density polyethylene (rLDPE) and high density polyethylene (rHDPE). Image Fortum.

Polykemi and their subsidiary Rondo Plast produce a range of recycled plastics, up to 100% recycled ingredients. Grades include polyamide (rPA), nylon, polypropylene (rPP), acrylonitrile butadiene styrene (rABS) and polycarbonate alloys (rPC/ABS). Image Polykemi.

The feedstock for UBQ is household waste, which is largely comprised of organic materials – everything from food residues and mixed plastics to cardboard, paper, and even dirty diapers, that would have otherwise been sent to landfill or incineration. Metals and minerals, which have high recyclability, are removed and sent over to traditional recycling streams. UBQ’s waste conversion technology breaks down the organic matter into its basic particulate constructs—lignin, cellulose, fibres, and sugars—and then reassembles them into a matrix. Residual plastics present in the waste stream melt and get mixed into the matrix to create a homogeneous and consistent composite thermoplastic material. Image UBQ.

Covestro Makrolon RE is a polycarbonate (PC) produced with some renewable content. Combined with the use of renewable energy, this helps to reduce the carbon footprint. It has identical clarity, and mechanical and visual properties, as regular PC. Image EVBox.

Borealis Borcycle is a recycled polypropylene (rPP) produced from post-consumer recycled (PCR) material. During mechanical recycling the waste plastic is separated by colour to ensure high visual quality material and enable the production of recycled light-coloured rPP. Image Borealis.

PolyVisions DuraPET is a recycled polyethylene terephthalate (rPET), polyester, derived mainly from waste packaging bottles (>90%). It a transparent polyester derived from consistent quality feedstock with very good visual and mechanical properties.

Bio-Fed M•Vera bio-based plastics by Akro Plastics are suitable for injection moulding and are used for coffee capsules, cutlery, cosmetic packaging, toys, plant clips and so on. Renewable grades are based on starch, cellulose, polylactic acid (PLA) and polyhydroxyalkanoates (PHA). Fossil-based types include polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS) and polycaprolactone (PCL). The amount of renewable content is tailored to the application. Image Bio-Fed (a branch of Akro Plastics).

MGG Polymers, which started out as a joint venture with MBA Polymers, have developed a range of techniques for separating complex post consumer mixed waste electrical and electronic equipment (WEEE). They produce grades of 100% recycled polypropylene (rPP), high impact polystyrene (rHIPS), acrylonitrile butadiene styrene (rABS) and polycarbonate alloy (rPC/ABS). Image MGG Polymers (Müller-Guttenbrunn Group).

Kombinat Konopny produce hemp for a range of fabrics, including blends with cotton, wool and viscose. They are suitable for automotive, interior, fashion and furniture applications.

Nonwoven suede for automotive, products, furniture and interiors made with recycled polyethylene terephthalate (PET), polyester, produced by Kolon Industries.

Wastea bio-based synthetic leather made with a mix of waste tea leaves, which are ordinarily burnt, and bio-based polyurethane resin (bio-PUR). It is 40-95% bio-based, depending on the requirements. Image Wastea.

OceanSafe have developed a 25-30% bio-based polyethylene terephthalate (PET), polyester, that is biodegradable in soil, marine and landfill. In marine water it biodegrades by >93% within 99 days, and is Cradle to Cradle Certified Gold. Alternatively, it can be recycled with regular polyester. It offers drop-in replacement for polyester as fill and fabric for fashion and interior applications. Image OceanSafe.

Modern Synthesis are developing a new class of materials using nanocellulose derived from bacterial fermentation. Komagataeibacter rhaeticus (K. rhaeticus), isolated from kombucha tea, is fed with sugar and in return creates bacterial cellulose (BC). It is produced as a film, which they combine with a natural textile to create a versatile range of non-woven materials. This unique approach to material design allows designers to precisely control the final look, feel and function of the textile, which can be further enhanced with finishing processes and naturally derived coatings. It is offers an animal free and plastic free alternative to leather, as well as other synthetic materials. Image Modern Synthesis.

NaturePlast produce a range of bio-based and biodegradable polyesters, such as polylactic acid (PLA) and polyhydroxyalkanoates (PHA), as well as bio-based polypropylene (bio-PP) and polyethylene (bio-PE). Their materials are suitable for a range of applications spanning packaging, products, automotive and textiles. Image NaturePlast.

FibraQ from BioFiber Tech is a wood fibre filler suitable for mixing with bioplastics and recycled plastic, as well as regular plastics like polypropylene (PP), in the production of bio-based composites. Image BioFiber Tech.

Terratek includes bio-based composites using fibres such as hemp, jute, sisal, bamboo and flax, instead of glass or carbon fibre. Green Dot Bioplastics produce a range of engineering polymers including compostable, flexible (elastomer) and natural fibre-reinforced grades. Image Green Dot Bioplastics.

Eastman Treva is a partially cellulose-based engineering material made with 45% bio-based ingredients. It has excellent surface gloss, clarity and tactility and is suitable for many of the same applications as polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). It was created to meet the requirements of packaging, eyeglass frames, wearable electronics, headphones and other personal devices and electronics housings and automotive parts. Image Eastman.

MBA Polymers have developed a unique set of processes that enable them to separate mixed plastic waste and convert it into plastic for new products. They produce a range of recycled materials including polypropylene (rPP), acrylonitrile butadiene styrene (rABS) and polystyrene (rPS). Image MBA Polymers.

Oryzite is a bio-filler produced from rice husk, a byproduct of food production. It is used to reduce the weight, cost and carbon footprint of plastics. Mixed with thermoplastics, such as polypropylene (PP), at up to 85%, it can have many benefits. Applications already include packaging, automotive parts, outdoor equipment, fashion accessories and product enclosures. However, it means the material is unlikely to be recycled end of life. Image Oryzite.

Uluu polyhydroxyalkanoates (PHA), biodegradable polyester, is produced using farmed seaweed feedstock. Image Uluu.

AirCarbon polyhydroxybutyrate (PHB), biodegradable polyester is produced by Newlight Technologies. They use a novel catalytic process based on microorganisms from the ocean. These microorganisms take oxygen from the air and carbon and hydrogen from methane and CO2, and combine these into molecules that make up PHB polymer. Image Newlight Technologies.

The Virent Bioforming process converts carbohydrate rich feedstocks, such as sugar beet and sugar cane, into bio-based hydrocarbons that can be used as the building blocks for plastics. The bio-based chemistry uses catalytic conversation to provide a drop-in replacement for petroleum derived products in the production of plastic like polyester (PET), nylon (PA) and polyurethane (PUR). Applications range from packaging and moulded products to textiles and films. Image Virent.

Mirel is a polyhydroxyalkanoate (PHA), bio-based and biodegradable polyester, produced by by Telles (dissolved 2012). A semi-crystalline PHA approved for food contact – from frozen foods to boiling water – it is suitable for injection moulding, film extrusion and thermoforming. In addition to packaging materials and food service items, it could be used to replace polystyrene (PS) in electronics packaging applications. Image Telles.

Ecopel Koba faux fur is produced using DuPont Sorona, a partially bio-based polytrimethylene terephthalate (PTT), polyester fibre, with up to one-third renewable ingredients.

Modern Meadow produce a synthetic leather they call Bio-Vera using a mix of recycled and bio-based ingredients. The scaffold structure is created with recycled car tyres. This is infused with Bio-Alloy, which is a mix of plant-based proteins and bio-polyurethane (PUR). A soy-based coating (Bio-Alloy Shield) provides the waterproof and breathable top layer. Image Modern Meadow.

Biophilica Treekind is a flexible, leather-like material, made from urban plant waste, agricultural waste and forestry waste. It is made up of lignocellulosic feedstock (leaves, agricultural waste and forestry waste) with a natural binder. It is coated with a bio-based material to make it waterproof. Available in a range of natural colours, it may also be modified with plant pigments as well as non-toxic natural pigments. It is home compostable, recyclable and estimated to have a very low resource footprint. Image Biophilica.

Parvati Valley Hemp Company produce hemp fibre for paper, textiles, garments, hempcrete building materials and lightweight composites. Image Parvati Valley Hemp Company.

LignoPure, a spin-off from the TVT Institute of the TUHH, produce sulphur-free lignin suitable as an ingredient in the production of bio-based plastics and composites. It is under development for a range of manufacturing processes like injection moulding, extrusion, melt spinning and 3D printing. Image LignoPure.

Banofi, Ban-o-Fi (banana fibre leather), plant-based leather is made with 50% banana fibres, 30% agricultural waste additives and 20% plastic. The textile is suitable for fashion, furniture, automotive and packaging applications. Image Banofi.

Evo bioplastic by Fulgar is made with a not for feeding castor oil plant grown spontaneously — a renewable resource that does not require high amounts of water nor subtracts arable land for food uses. The fibre is lightweight, moisture wicking and resilient, and available in a range of vivid colours. Image Fulgar.

UPM Formi EcoAce is a bio-based polypropylene (bio-PP) produced from bio-based naphtha, which is made from crude tall oil, a byproduct of the paper pulp process. The bio-composite version contains certified wood fibre (40-60%) or cellulose fibres (30-50%). Based almost entirely on renewable materials, it provides a drop-in replacement for fossil-based PP. It is recyclable and suitable for food contact applications.

ThermHex uses the EconCore developed production technique for creating continuous polypropylene (PP) honeycomb in thicknesses ranging from 3-28 mm. Image ThermHex.

Super Sap by Entropy Resins is a modified epoxy that contains 15-37% bio based ingredients (bio-EP). These ingredients are sourced from waste streams, such as wood pulp or biofuel production. A range of resins exist, suitable as replacements for conventional petroleum-derived epoxies, from ultra-clear casting through laminating and compression moulding.

Sorona by DuPont is a partially bio-based polytrimethylene terephthalate (PTT), polyester. With up to one-third renewable ingredients, it is available as a polyester fibre and injection moulded compound. As such it is suitable for a range of applications, from interior textiles and carpets to faux fur, through product housings and engineering components. Image DuPont.

Soleic partially bio-based and biodegradable polyurethane resin (bio-PUR) by Algenesis. The monomers are created from algae oil and engineered to biodegrade. Currently 52% bio-based, there is development ongoing to increase this to 98%. Image Algenesis.

ReSound bio-based thermoplastic elastomer (bio-TPE) by Avient (formerly PolyOne) utilise between 40-50% content derived from sugarcane, and offer hardness levels and performance comparable to standard TPE. Image Avient.

Reishi fine mycelium fabric by MycoWorks provides an alternative to animal leather and plastic-based textiles made using polyurethane (PU) or polyvinyl chloride (PVC). This luxury mycelium leather that looks and feels like fine animal leather but with much lower environmental impact. Image MycoWorks.

Recycled carbon fibre (rCF) by Gen 2 Carbon is produced from waste generated in production – around 30% of produced carbon fibre ends up as waste at some point in the process. Companies such as Gen 2 Carbon (formerly ELG Carbon Fibre) convert this waste into rCF. The cost is around 40% less than industrial grade virgin carbon fibre and Gen 2 Carbon, who reclaim carbon fibre by pyrolysis, say their fibre retains 90% of its tensile strength and 100% stiffness. Image Gen 2 Carbon.

Mylo mushroom leather by Bolt Threads is produced with mycelium, grown in a vertical farming facility powered by 100% renewable energy and transformed it into a material that looks and feels like animal leather. Image Bolt Threads.

Fruitleather is produced from mango waste mixed with additives and finished with a waterproof coating. It is backed with organic cotton to provide strength. This vegan leather is suitable as an alternative to animal leather in many situations, including fashion, footwear and furniture applications. Image Fruitleather.

Ekoa by Lingrove includes a range of flax fibre reinforced composites suitable for processing via standard composite manufacturing techniques such as wet lay-up, compression moulding, infusion and resin transfer moulding (RTM). Flax (linen) is a renewable and sustainable fibre that offers good vibration dampening and high strength to weight in composite applications. Image Lingrove.

Econyl by Aquafil is a regenerated polyamide (PA), nylon, coming entirely from waste that is chemically recycled. This innovative technique is different from conventional mechanical recycling and it guarantees the same quality as standard nylon. Image Aquafil.

Copper mining and smelting have a significant carbon footprint. The global average, according to the International Copper Association (ICA), is 2.3 kgCOe/kg. Boliden low-carbon copper, produced with renewable energy and recycled contents (up to 100%), has a reduced carbon footprint of 1.5 kgCO2e/kg. The primary raw material for Boliden’s recycled copper is used electronics. Image Boliden.

Biopure bio-recycled polyester by Protein Evolution is made from rigid packaging waste and industrial textile strappings. Protein Evolution uses AI-designed enzymes to break down polyester (PET) waste into the raw materials of new polyester that are indistinguishable to the petroleum-derived raw materials used in polyester manufacturing. The process is capable of handling a variety of waste streams, from plastic bottles and clam-shells, to industrial textiles and garments. Image Stella McCartney.

BioPBS polybutylene succinate (PBS) produced in a joint venture between Mitsubishi Chemical Company and PTT Global Chemical Public Company. This grade of biodegradable co-polyester is derived from biomass, such as sugarcane and cassava, and decomposes into water and CO2 with the microorganism under the soil in ambient conditions (30 degC) – it is suitable for home composting and doesn’t require any specialised facilities. PBS has relatively good heat resistance compared to other biodegradable plastics and can be converted into a fibre. It is applied as a coating to paper, such as for disposable coffee cups, as an injection moulding resin and flexible packaging. Image Mitsubishi.

Bcomp have developed flax fibre reinforcement solutions, including powerRibs and ampliTex, suitable for processing via standard composite manufacturing techniques such as wet lay-up, compression moulding, infusion and resin transfer moulding (RTM). Flax (linen) is a renewable and sustainable fibre that offers good vibration dampening and high strength to weight in composite applications. Image Bcomp.

Avantium polyethylene furanoate (PEF), bio-based polyester is suitable as a fossil-free replacement for polyethylene terephthalate (PET), polyester, such as in packaging applications. It is recyclable, but not biodegradable. Image Avantium.

DSM Arnitel Eco is a high-performance partially bio-based thermoplastic co-polyester elastomer (bio-TPC) made with rapeseed oil. It is suitable for use in consumer products (providing soft touch in 2k injection moulding applications), sports, textile membranes, automotive, furniture (suspension fabrics) and packaging. Image Sympatex.

AppleSkin by Vegatex is a synthetic leather produced with a mix of plant-based materials (by-product of apple processing for the beverage industry) mixed with water-based polyurethane resin (PUR) on a Tencel Lyocell, or recycled polyester (rPET), textile backing. Similar materials from Vegatex include LemonSkin made with by-products of apples and lemons from the beverage industry, and BarleySkin made from brewer’s spent grains. Image Vegatex.

Akro Plastics Akromid partially bio-based polyamide (bio-PA), is a range of nylons (PA6, PA610, PA11) manufactured from castor oil, corn or sunflower oil, for example. Image Akro Plastics.