Periodic Reporting for period 2 - Waste2BioComp (Converting organic waste into sustainable bio-based components)
Reporting period: 2023-12-01 to 2025-05-31
W2BC was initiated to address urgent environmental challenges and leverage opportunities for industrial transformation in line with Europe’s ambition for climate neutrality by 2050. The project targets manufacturing sectors, particularly textiles, packaging, and footwear, which are substantial contributors to global pollution and resource use.
A fundamental concern in these sectors is the persistent reliance on petrochemical-based materials, which are non-renewable, non-biodegradable, and pose long-term threats to both environmental and resource sustainability. The project recognized the critical need to substitute such materials with renewable, bio-based alternatives to meet EU carbon reduction targets and support the wider shift to a sustainable and circular economy.
However, transitioning from conventional, fossil-based materials to innovative biopolymers and bio-based compounds is not straightforward. Bio-based materials often have different processing characteristics, so their adoption at an industrial scale demands the development or adaptation of manufacturing routes. In parallel, market and regulatory forces are driving the search for cost-competitive, high-performance bio-based alternatives. Manufacturers and brands are responding to increasing regulatory pressure and growing consumer demand for sustainable solutions.
To tackle these issues, W2BC demonstrated, at relevant scale, the feasibility of producing diverse bio-based products, including shoe soles and insoles, flexible packaging films, rigid composites, technical textiles, and printed materials, using innovative manufacturing technologies. By covering the full product life cycle, from R&I on bio-based feedstocks (like PHAs, microparticles, and pigments) through to manufacturing, toxicity and sustainability assessments, and circular strategies for recycling and remanufacturing, the project ensures a holistic approach to closing the materials loop.
The development of dedicated training materials ensures that knowledge and skills for biomaterial-based manufacturing are disseminated, underpinning sectoral transformation and societal acceptance.
A fundamental concern in these sectors is the persistent reliance on petrochemical-based materials, which are non-renewable, non-biodegradable, and pose long-term threats to both environmental and resource sustainability. The project recognized the critical need to substitute such materials with renewable, bio-based alternatives to meet EU carbon reduction targets and support the wider shift to a sustainable and circular economy.
However, transitioning from conventional, fossil-based materials to innovative biopolymers and bio-based compounds is not straightforward. Bio-based materials often have different processing characteristics, so their adoption at an industrial scale demands the development or adaptation of manufacturing routes. In parallel, market and regulatory forces are driving the search for cost-competitive, high-performance bio-based alternatives. Manufacturers and brands are responding to increasing regulatory pressure and growing consumer demand for sustainable solutions.
To tackle these issues, W2BC demonstrated, at relevant scale, the feasibility of producing diverse bio-based products, including shoe soles and insoles, flexible packaging films, rigid composites, technical textiles, and printed materials, using innovative manufacturing technologies. By covering the full product life cycle, from R&I on bio-based feedstocks (like PHAs, microparticles, and pigments) through to manufacturing, toxicity and sustainability assessments, and circular strategies for recycling and remanufacturing, the project ensures a holistic approach to closing the materials loop.
The development of dedicated training materials ensures that knowledge and skills for biomaterial-based manufacturing are disseminated, underpinning sectoral transformation and societal acceptance.
W2BC achieved breakthrough discoveries in bio-based materials and their manufacturing, namely developing/producing:
• PHAs with varied crystallinity using both chemical and fermentation methods
• a scalable process for producing active bio-based microparticles to incorporate into rigid bioplastics, enabling controlled release and antioxidant properties
• antimicrobial core-shell nanocapsules (NCs) and three bio-based pigments, one at ton-scale, via combined fermentation and chemical synthesis
• 6 ink formulations for cellulosic and polyester textiles, leather, paper, and foam substrates
• 2D and 3D inkjet equipment supporting print-on-demand for garments and shoes
• PHA foams with three hardness levels (94% bio-content)
• biodegradable three-layer shoe insoles
• PU foams containing up to 75% bio-based content
• over 300 m of biodegradable flexible plastic film (70% PHA, 30% PLA) via blown extrusion
• biodegradable rigid plastics with 2% MP loading by industrial melting processing (extrusion, injection, thermoforming), demonstrating prolonged active agent release up to 1000 h and antioxidant effects
• spray-coated textiles using PHA dispersions and PHA-based knife coatings.
• 2 methods for indigo ink removal on printed textiles
• biodegradable prototypes for each value chain
Three depolymerization strategies were tested on commercial materials, enabling biogenic and chemical repolymerization to regenerate PHAs. Additionally, PHAs were chemically modified with various alcohols to synthesize bio-based polyester polyols for PU foam production.
W2BC generated substantial scientific outputs: 8 open-access journal articles, 2 conference publications, 40 presentations at scientific and industry events, 3 public dissemination events, 2 master’s theses, 2 PhD dissertations, and patent applications.
• PHAs with varied crystallinity using both chemical and fermentation methods
• a scalable process for producing active bio-based microparticles to incorporate into rigid bioplastics, enabling controlled release and antioxidant properties
• antimicrobial core-shell nanocapsules (NCs) and three bio-based pigments, one at ton-scale, via combined fermentation and chemical synthesis
• 6 ink formulations for cellulosic and polyester textiles, leather, paper, and foam substrates
• 2D and 3D inkjet equipment supporting print-on-demand for garments and shoes
• PHA foams with three hardness levels (94% bio-content)
• biodegradable three-layer shoe insoles
• PU foams containing up to 75% bio-based content
• over 300 m of biodegradable flexible plastic film (70% PHA, 30% PLA) via blown extrusion
• biodegradable rigid plastics with 2% MP loading by industrial melting processing (extrusion, injection, thermoforming), demonstrating prolonged active agent release up to 1000 h and antioxidant effects
• spray-coated textiles using PHA dispersions and PHA-based knife coatings.
• 2 methods for indigo ink removal on printed textiles
• biodegradable prototypes for each value chain
Three depolymerization strategies were tested on commercial materials, enabling biogenic and chemical repolymerization to regenerate PHAs. Additionally, PHAs were chemically modified with various alcohols to synthesize bio-based polyester polyols for PU foam production.
W2BC generated substantial scientific outputs: 8 open-access journal articles, 2 conference publications, 40 presentations at scientific and industry events, 3 public dissemination events, 2 master’s theses, 2 PhD dissertations, and patent applications.
The Waste2BioComp project has achieved major advances in both scientific and practical arenas, delivering significant progress towards environmental and industrial sustainability in the textile, packaging, and footwear value chains. W2BC’s results surpass current commercial offerings in several respects: the availability and applicability of PHAs; the development of bio-based antimicrobial nanocapsules and microparticles without fossil-derived components; new bio-based pigments with improved light-fastness suitable for inkjet applications; and bio-based foams, packaging films, and textile coatings as fossil-free alternatives.
These materials demonstrated marked reductions in carbon footprint (GWP100: 23–76%) and energy use (up to 96%) throughout production and use phases and were validated for biodegradability (UNE-EN ISO 17556:2020) and non-toxicity. The project also pioneered solvent-free PHA synthesis for safer, greener production, and achieved a 29% cost reduction in PHA production compared to market norms, signaling high market uptake potential.
W2BC’s work resulted in a diverse range of pilot-scale bio-based materials and functional, safe, and biodegradable end-products, which were fully validated for performance and environmental impact. The project’s broad outreach, training, and engagement efforts heightened societal awareness, supported workforce readiness, and drove both market demand and supply chain preparedness.
Realizing the full impact of W2BC’s innovations will require continued research and upscaling, including expanded pilot trials and real-world validation, targeted investment for industrial growth, robust IPR protection for new technologies, and active collaboration with standardization bodies and regulators to secure recognition and incentives for bio-based products.
These materials demonstrated marked reductions in carbon footprint (GWP100: 23–76%) and energy use (up to 96%) throughout production and use phases and were validated for biodegradability (UNE-EN ISO 17556:2020) and non-toxicity. The project also pioneered solvent-free PHA synthesis for safer, greener production, and achieved a 29% cost reduction in PHA production compared to market norms, signaling high market uptake potential.
W2BC’s work resulted in a diverse range of pilot-scale bio-based materials and functional, safe, and biodegradable end-products, which were fully validated for performance and environmental impact. The project’s broad outreach, training, and engagement efforts heightened societal awareness, supported workforce readiness, and drove both market demand and supply chain preparedness.
Realizing the full impact of W2BC’s innovations will require continued research and upscaling, including expanded pilot trials and real-world validation, targeted investment for industrial growth, robust IPR protection for new technologies, and active collaboration with standardization bodies and regulators to secure recognition and incentives for bio-based products.