Building a sustainable & circular economy through innovative, biobased manufacturing lines

Project Information

NewWave

Grant agreement ID: 101058369

DOI

10.3030/101058369

Project closed

EC signature date 13 May 2022

Start date 1 April 2022

End date 31 March 2026

Funded under

• Digital, Industry and Space

Total cost

€ 5 057 580,00

EU contribution

€ 5 057 580,00

Coordinated by

B.T.G. BIOMASS TECHNOLOGY GROUP BV
Netherlands

Periodic Reporting for period 3 - NewWave (Building a sustainable & circular economy through innovative, biobased manufacturing lines)

Reporting period: 2025-04-01 to 2026-03-31

Summary of the context and overall objectives of the project

NewWave contributed to building a circular economy by introducing sustainable raw materials in four different manufacturing lines (ML), replacing toxic chemicals, and lowering the environmental footprint of the products. The innovative approach of NewWave was to apply thermo-chemical fractionation (TCF) to unlock and fractionate residual biomass. TCF combines fast pyrolysis of the biomass with subsequent fast pyrolysis oil separation, keeping the key chemical functionalities in separate, depolymerized fractions. The fractions were used in the manufacturing lines producing engineered wood panels, furan base-chemicals, polyols and polyurethanes, and modified/engineered wood. These lines were not chosen ‘at random’, rather they evolved from previous research and technology development work. The products produced in the manufacturing lines were used to enhance the sustainability of building materials in the construction industry. NewWave aimed at wood-based materials including Cross Laminated Timber (CLT) to replace steel and concrete as structural components, modified/engineered wood to replace tropical hardwood or chemically treated wood for outdoor use, and Medium Density Fibreboard (MDF) and plywood for interior usage. Toxic chemicals like formaldehyde and creosote were replaced by non-toxic, bio-based alternatives. Within the project, a small demonstration project was built with these materials to show the products and test their durability. NewWave showed a unique blend of European companies and institutes, it consists of seven innovative SME’s, two academic partners and two large industrial companies representing the four different but interlinked manufacturing lines. The project was led by BTG Biomass Technology Group BV from the Netherlands. The project, which started in April 2022 did run for four years, and was funded under the EU framework programme Horizon Europe.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project finished on time; there were no deviations. All fractions and samples were delivered (WP2), circularity tests concerning waste-water treatment have been conducted and showed to be successful. The conversion of sugars to HMF (ML2) was performed on bench-scale, further HMF purification methods need to be developed. Green Solvents (ML2): These are the products closest to the market, having already reached TRL 9. With the launch of a commercial hydrogenation unit, solvents like 2-MeTHF are ready for immediate use in the pharmaceutical and agrochemical industries. Modified Wood (ML4): Currently at TRL 6. While pilot results are excellent (durability class 2), further field testing (such as EN 252 stake tests) is required (ongoing) to confirm durability over multi-decade periods in ground contact. Plywood & MDF resins (ML3): These stand between TRL5 and 6. While partial phenol replacement by lignin is already promising, creating 100% bio-based resins (entirely replacing formaldehyde with HMF) requires further research to reduce production times and energy costs, which are currently too high for industrial competitiveness. Polyols and PUR's (ML1) stand between TRL 4 and 5. Rigid Polyurethane Foams: Used as insulating cores for sandwich panels, demonstrating mechanical properties in line with fossil-based standards. Bio-based Adhesives: two systems formulated for bonding Cross-Laminated Timber (CLT) panels, based on two different bio-polyols synthesized using FPBO-derived glycols fully replacing petrochemical polyols. The glycols could be produced in high yield from the pyrolytic sugars. LCA & LCC studies were finished. All deliverables have been submitted and all milestones were reached.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The project’s central vision was the radical transformation of current fossil-based production lines into new bio-based value chains capable of upcycling biomass residues (such as sawdust) and end-of-life products. Through technological innovation, NewWave aimed to reduce the environmental footprint of construction materials while ensuring mechanical and physical performance equal to or greater than that of the traditional products. The overall concept of the project revolved around four manufacturing lines (ML) that developed a series of intermediate and end products. The work in the ML was possible thanks to the technology at the core of NewWave: Thermo-Chemical Fractionation (TCF). A fundamental pillar of this mission was the replacement of toxic and hazardous chemicals—including formaldehyde, creosote, and copper salts—with bio-sourced, non-toxic, and fully recyclable alternatives. This approach not only makes materials safer for end-users but also promotes a healthier working environment and reduces air pollution. Driven by a consortium of 11 European partners, bringing together research excellence and industrial leaders, the project has advanced these technologies to a new maturity level (TRL-5/6). The validity of this vision has been demonstrated concretely through the construction of a real architectural model (mock-up) in Slovenia, where the new bio-based materials have been tested for durability and performance in outdoor conditions. The consortium wishes that this marks the start of a "new wave of doing things” where construction stops consuming finite resources, by becoming more circular and transforming itself into an engine for natural regeneration.

The NewWave project has successfully demonstrated that transforming wood waste into high-performance bio-based materials is technically feasible. However, moving from prototype to industrial production requires a strategic path that combines infrastructure scaling, cost optimization, and long-term validation.

Industrial Scalability: Europe’s First Bio-Refinery: The cornerstone of the project’s commercial future is the scaling up of the Thermo-Chemical Fractionation (TCF) process. The construction of the first industrial-scale Fast Pyrolysis Bio-Oil (FPBO) fractionation unit is planned for 2027 at Biorefinery Twente in the Netherlands. This infrastructure will be essential to ensure a consistent supply of bio-based lignin and sugars at competitive prices.