Periodic Reporting for period 1 - WoTe-Agoprene (Agoprene - biofoams for the future furniture)
Période du rapport: 2023-07-01 au 2024-06-30
We are surrounded by products that contain substances that were once pumped up from the ground. The substances are also known as petrochemicals, because we extract them from petroleum. Petrochemicals turn oil and gas into all sorts of daily products – such as plastics, fertilizers, packaging, clothing, digital devices, medical equipment, detergents or tyres – and are integral to modern societies. Petrochemicals are rapidly becoming the largest driver of global oil consumption (Energy & Climate, 2018). They are set to account for more than one third of the growth in oil demand by 2030, and nearly half by 2050, ahead of trucks, aviation and shipping. The difficulty of finding alternatives to petrochemicals in applications such as foam materials, is an important factor for the robust growth in demand. The production of petrochemicals and their derivatives absorbs an increasing share of the world's oil and gas - about 14% for oil and 8% for gas. However, with the market for petrochemical products expanding further as the global economy develops, the future of the petrochemical industry is of great importance for both global energy security and the environment (IEA, 2018).
Agoprene develops furniture foam from seaweed, to help the furniture industry reduce their need for petrochemicals. Our market research of the furniture industry has confirmed a growing demand for sustainable materials, especially because they are completely dependent on petrochemicals today. An armchair, for example, emits an average of 43 kg CO2e, almost half of which is due to the furniture foam. Globally, furniture foam, which is derived from petroleum, accounts for 105 million tonnes of CO2 emissions annually. Petroleum-based foam is so widely used for cushioning because it is cheap.That has created a class of disposable furniture items that litter our landscapes and fill our garbage dumps.
Until now the solution has been to replace some of the petroleum-based polyols with bio-based polyols in the foam. Polyols are one of the ingredients in petroleum based foam. Unfortunately, this solution has only been able to replace 20% of the petroleum used in the foam, leaving the consumer with the impression that it is a bio-based product, when it is essentially a petroleum based product with some bio content (Sustainable Furnishings, 2010). Agoprene is not blaming the furniture industry, because until now, no better alternative has existed.
It is known that harvesting fibrous plants and producing plant fibers will remove CO2. With this as a starting point, Agoprene will create a mechanically superior foam material with zero carbon emissions. Agoprene aims to prove the technology and move the material one step closer to commercialization. The main goal for Women TechEU is to take the material from the current lab-scale production to production under real operating conditions. This includes the following: develop a large scale production method and test the production process under real operating conditions.
Agoprene develops furniture foam from seaweed, to help the furniture industry reduce their need for petrochemicals. Our market research of the furniture industry has confirmed a growing demand for sustainable materials, especially because they are completely dependent on petrochemicals today. An armchair, for example, emits an average of 43 kg CO2e, almost half of which is due to the furniture foam. Globally, furniture foam, which is derived from petroleum, accounts for 105 million tonnes of CO2 emissions annually. Petroleum-based foam is so widely used for cushioning because it is cheap.That has created a class of disposable furniture items that litter our landscapes and fill our garbage dumps.
Until now the solution has been to replace some of the petroleum-based polyols with bio-based polyols in the foam. Polyols are one of the ingredients in petroleum based foam. Unfortunately, this solution has only been able to replace 20% of the petroleum used in the foam, leaving the consumer with the impression that it is a bio-based product, when it is essentially a petroleum based product with some bio content (Sustainable Furnishings, 2010). Agoprene is not blaming the furniture industry, because until now, no better alternative has existed.
It is known that harvesting fibrous plants and producing plant fibers will remove CO2. With this as a starting point, Agoprene will create a mechanically superior foam material with zero carbon emissions. Agoprene aims to prove the technology and move the material one step closer to commercialization. The main goal for Women TechEU is to take the material from the current lab-scale production to production under real operating conditions. This includes the following: develop a large scale production method and test the production process under real operating conditions.
The Women TechEU project undertook a series of well-coordinated activities aimed at developing an environmentally friendly foam material and achieving key milestones. The main goal was to produce the material on a market-relevant scale under real operating conditions, in collaboration with pilot customers, to demonstrate its technical requirements and environmental benefits compared to current alternatives.
During the project, several critical activities were carried out:
First, the team built the pilot production facility in August 2023, a significant milestone in the project timeline. This pilot facility allowed the team to move beyond the laboratory scale and focus on fine-tuning the production process. Throughout the project period, efforts were dedicated to finding the right temperatures and environment for the foam production, as well as scaling the process from lab-scale to the current pilot production capability. The facility can now produce 200 kg of foam weekly. Funding was instrumental in supporting these activities, including acquiring necessary materials, renting production facilities, and compensating participants involved in the pilot production.
Next, the project focused on advancing the foam material to TRL 7, which indicates a prototype near to operational level. This step involved intensive research activities, the procurement of advanced testing equipment, and engagement with industry experts. Funding was utilized to support these research activities. The Materials Scientists conducted experiments to enhance the material's properties, and the Quality Control Specialists ensured that the material complied with industry standards.
The third major activity was securing additional funding to extend the project's operational timeline. This involved identifying potential funding sources and developing comprehensive proposals to present to investors. Initial project funding was crucial in developing these proposals and conducting negotiations.
Lastly, the project ensured the protection of the company's IPR. This involved legal consultations and the preparation of patent applications to secure the innovations developed during the project. Funding supported these legal activities. The legal team managed the IPR-related activities, while the R&D team provided the technical details necessary for the patent applications.
During the project, several critical activities were carried out:
First, the team built the pilot production facility in August 2023, a significant milestone in the project timeline. This pilot facility allowed the team to move beyond the laboratory scale and focus on fine-tuning the production process. Throughout the project period, efforts were dedicated to finding the right temperatures and environment for the foam production, as well as scaling the process from lab-scale to the current pilot production capability. The facility can now produce 200 kg of foam weekly. Funding was instrumental in supporting these activities, including acquiring necessary materials, renting production facilities, and compensating participants involved in the pilot production.
Next, the project focused on advancing the foam material to TRL 7, which indicates a prototype near to operational level. This step involved intensive research activities, the procurement of advanced testing equipment, and engagement with industry experts. Funding was utilized to support these research activities. The Materials Scientists conducted experiments to enhance the material's properties, and the Quality Control Specialists ensured that the material complied with industry standards.
The third major activity was securing additional funding to extend the project's operational timeline. This involved identifying potential funding sources and developing comprehensive proposals to present to investors. Initial project funding was crucial in developing these proposals and conducting negotiations.
Lastly, the project ensured the protection of the company's IPR. This involved legal consultations and the preparation of patent applications to secure the innovations developed during the project. Funding supported these legal activities. The legal team managed the IPR-related activities, while the R&D team provided the technical details necessary for the patent applications.