Spotlight

Syklo biocomposite made with recycled waste

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.

Spotlight

MuCell lightweight energy absorbing foams

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.

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Hexpol Dryflex Circular recycled elastomers

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.

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Bolton Metal low carbon steel produced by electrolysis

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.

Spotlight

Uncaged Innovations bio-based leather alternative

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.

Spotlight

Made of Air carbon-negative additive for plastics

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.

Spotlight

MuCell polymer reduction technology

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.

Spotlight

UBQ thermoplastic additive made from household waste

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.

Spotlight

Bio-based and renewable plastic blends

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).

 

Spotlight

NaNea biodegradable polyester fibre

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.

Spotlight

Bacterial cellulose textiles by Modern Synthesis

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.

Spotlight

Eastman Treva cellulose-based bioplastic

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.

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Oryzite rice husk bio-filler for thermoplastics

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.

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Virent bio-based hydrocarbons for bioplastics

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.

Spotlight

Mirel polyhydroxyalkanoate (PHA), biodegradable polyester

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.

Spotlight

Treekind plant-based leather by Biophilica

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.

Spotlight

UPM Formi EcoAce bio-based polypropylene (bio-PP)

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.

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Reishi fine mycelium fabric

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.

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Recycled carbon fibre (rCF)

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.

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Fruitleather

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.

Spotlight

Ekoa flax textiles by Lingrove

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.

Spotlight

Boliden recycled copper

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.

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Biopure bio-recycled polyester by Protein Evolution

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.

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BioPBS biodegradable co-polyester by Mitsubishi

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.

Spotlight

Bcomp flax fibre composite reinforcement

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.

Spotlight

AppleSkin by Vegatex

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.