This innovation is a major step toward creating truly circular materials and eliminating the reliance on fossil fuels in polyurethane production.
In a major development for the sustainable materials industry, Algenesis Labs announced today the successful commissioning of a pilot plant for its new Bio-Iso™ technology. This innovation marks a significant departure from traditional polyurethane chemistry, offering a 100% biogenic carbon isocyanate derived entirely from plants. The company's new process eliminates the use of highly toxic phosgene gas, which has long been a staple in the manufacturing of conventional, petroleum-based Isocyanates.
Polyurethanes are a versatile class of polymers found in everything from foams and adhesives to coatings and elastomers. For decades, the global industry has been dependent on fossil fuels and hazardous chemical processes to create the necessary components, primarily isocyanates. This new technology from Algenesis Labs, which is both modular and scalable, offers a solution that not only matches the performance of its petroleum-based counterparts but also introduces a new standard for safety and environmental responsibility.
Dr. Stephen Mayfield, CEO of Algenesis Labs, highlighted the transformative nature of the new material. "This isn't just a greener alternative," he stated. "Bio-Iso™ represents a fundamental shift in how we think about polyurethane production." Dr. Mayfield explained that when combined with Algenesis’ existing Soleic® polyol, Bio-Iso™ makes it possible to create a 100% bio-based Thermoplastic Polyurethane (TPU). This was validated through an ASTM D6866-24 analysis by Beta Analytic, an international standard test for determining the bio-based content of materials using radiocarbon analysis.
The significance of the Bio-Iso™ launch extends beyond its plant-based origin. The phosgene-free manufacturing process addresses a long-standing safety concern in the Chemical Industry. Phosgene, a colorless and highly toxic gas, has historically been a critical component in isocyanate synthesis. By developing a green chemistry alternative, Algenesis Labs is not only reducing greenhouse gas emissions but also creating a safer production chain for manufacturers.
Algenesis Labs is actively seeking strategic partners for the global industrial-scale commercialization of the technology. The company is offering priority access to Bio-Iso™ materials and future volume options to early collaborators, positioning them as leaders in the transformation of the Urethane Industry. This launch is the latest milestone in the company's mission to combat microplastic pollution and reduce the world's reliance on fossil fuels. With key benefits including a lower carbon footprint, petroleum-comparable performance, and the ability to biodegrade at end-of-life without leaving behind persistent microplastics, Bio-Iso™ sets the stage for a new generation of truly circular materials.
