Periodic Reporting for period 3 - BIOMAT (An Open Innovation Test Bed for Nano-Enabled Bio-Based PUR Foams and Composites)
Reporting period: 2024-01-01 to 2024-12-31
Polyurethane (PUR) products used in construction, automotive, and furniture sectors are traditionally fossil-based and often lack performance and sustainability. BIOMAT addressed this by establishing an Open Innovation Test Bed (BIOMAT-TB) to support SMEs and industries in developing nano-enabled bio-based PUR foams and composites. Through a Single Entry Point (SEP), users accessed pilot-scale production lines and services such as characterisation, nanosafety, standardisation, business planning, and mentoring.
The project was structured around nine objectives:
O1 – Establishment of the BIOMAT-TB and SEP:
A fully operational test bed and SEP platform were created, with 13 partners providing services. A business model and sustainability plan were developed.
O2 – Implementation of the Open Tender:
Two Open Calls attracted 14 applications. 7 SMEs received tailored technical and business services, validating the SEP’s functionality.
O3 – Development of Digital Twin Pilots (DTP) and inline monitoring:
A Digital Twin Platform was developed with 6 generic and 22 ad-hoc models. Inline spectroscopic sensors (UV-Vis and NIR) enabled real-time monitoring and optimisation, improving reproducibility by 27% and reducing offline measurements by 60%.
O4 – Scale-up and characterisation of foam components:
12 pilot lines were upgraded (TRL 6-7) to produce bio-based components such as polyols, lignocellulosic adhesives, and nanofillers, demonstrating feasibility at pre-commercial scale.
O5 – Scale-up and validation of bio-based PUR foams:
Soft, semi-soft, rigid, and spray foams, as well as insulation aerogels, were scaled up and validated, showing improved thermal and mechanical performance.
O6 – Demonstrators in operational environments:
10 demonstrators were validated. In construction, mock-ups in Spain and Latvia showed improved insulation. In automotive, seat components met industry standards. In furniture, products showed high comfort and durability.
O7 – Recycling, nanosafety, and standardisation:
Microwave-assisted glycolysis achieved 53% energy savings. Recyclates were reused without performance loss. Five air monitoring campaigns and toxicological assessments confirmed safety. A new standard (CWA 50751:2024) was published.
O8 – Environmental and economic sustainability:
LCA, LCC, and SLCA confirmed lower environmental impact and competitive costs. Market analysis and value chain assessment supported the business plan.
O9 – Dissemination, exploitation and communication:
The project produced 20 publications, participated in 65 events, attracted over 11,000 SEP possible clients, and created 3 demonstration videos. A strategic exploitation plan was developed, with 11 technologies ready for transfer and a customer database of over 9,000 contacts.
BIOMAT demonstrated that sustainable, high-performance PUR materials can be developed and scaled through a collaborative, innovation-driven ecosystem, contributing to EU goals for circular economy and climate neutrality.
The project was structured around nine objectives:
O1 – Establishment of the BIOMAT-TB and SEP:
A fully operational test bed and SEP platform were created, with 13 partners providing services. A business model and sustainability plan were developed.
O2 – Implementation of the Open Tender:
Two Open Calls attracted 14 applications. 7 SMEs received tailored technical and business services, validating the SEP’s functionality.
O3 – Development of Digital Twin Pilots (DTP) and inline monitoring:
A Digital Twin Platform was developed with 6 generic and 22 ad-hoc models. Inline spectroscopic sensors (UV-Vis and NIR) enabled real-time monitoring and optimisation, improving reproducibility by 27% and reducing offline measurements by 60%.
O4 – Scale-up and characterisation of foam components:
12 pilot lines were upgraded (TRL 6-7) to produce bio-based components such as polyols, lignocellulosic adhesives, and nanofillers, demonstrating feasibility at pre-commercial scale.
O5 – Scale-up and validation of bio-based PUR foams:
Soft, semi-soft, rigid, and spray foams, as well as insulation aerogels, were scaled up and validated, showing improved thermal and mechanical performance.
O6 – Demonstrators in operational environments:
10 demonstrators were validated. In construction, mock-ups in Spain and Latvia showed improved insulation. In automotive, seat components met industry standards. In furniture, products showed high comfort and durability.
O7 – Recycling, nanosafety, and standardisation:
Microwave-assisted glycolysis achieved 53% energy savings. Recyclates were reused without performance loss. Five air monitoring campaigns and toxicological assessments confirmed safety. A new standard (CWA 50751:2024) was published.
O8 – Environmental and economic sustainability:
LCA, LCC, and SLCA confirmed lower environmental impact and competitive costs. Market analysis and value chain assessment supported the business plan.
O9 – Dissemination, exploitation and communication:
The project produced 20 publications, participated in 65 events, attracted over 11,000 SEP possible clients, and created 3 demonstration videos. A strategic exploitation plan was developed, with 11 technologies ready for transfer and a customer database of over 9,000 contacts.
BIOMAT demonstrated that sustainable, high-performance PUR materials can be developed and scaled through a collaborative, innovation-driven ecosystem, contributing to EU goals for circular economy and climate neutrality.
The BIOMAT project established a comprehensive Open Innovation Test Bed (OITB) to support the development and industrial uptake of nano-enabled bio-based polyurethane (PUR) foams and composites. The initiative focused on building a robust operational structure, scaling up innovative technologies, validating them in real-world applications, and ensuring their sustainability and market readiness.
The SEP was validated through two Open Calls, which attracted 14 applications and led to the delivery of 7 complete service packages to SMEs across Europe. A business model and pricing strategy were developed to ensure long-term affordability and sustainability.
12 pilot lines were upgraded to produce a wide range of bio-based PUR components and foams, including bio-polyols, lignocellulosic adhesives, functionalized nanofillers, prepregs, soft and rigid foams, and insulation aerogels. These were integrated into a Digital Twin Platform with 22 ad-hoc and 6 generic models for real-time process control and predictive analytics. Some lines were also equipped with inline spectroscopic monitoring systems.
10 demonstrators were validated in operational environments:
- In construction, mock-ups in Spain and Latvia showed improved insulation and energy efficiency.
- In automotive, seat cushions, headrests, and steering wheels met industry standards.
- In furniture and bedding, mattresses, sofas, and chairs demonstrated high comfort, resilience, and sustainability.
Advanced recycling technologies were implemented, including microwave-assisted glycolysis, which achieved up to 53% energy savings. Recyclates were reintegrated into new foam formulations. Nanosafety assessments were conducted across the value chain, and a new standard (CWA 50751:2024) was published to guide data-driven production management.
Sustainability assessments (LCA, LCC, SLCA) confirmed the lower environmental impact and competitive production costs of BIOMAT materials. The project achieved strong visibility: 20 peer-reviewed publications, 65 international events, over 11,000 website visits, and 3 demonstration videos. A strategic exploitation plan was developed, with 11 technologies ready for transfer and a customer database of over 9,000 contacts.
BIOMAT-TB is now positioned as a reference infrastructure for the development and commercialisation of sustainable, nano-enabled bio-based PUR materials in Europe.
The SEP was validated through two Open Calls, which attracted 14 applications and led to the delivery of 7 complete service packages to SMEs across Europe. A business model and pricing strategy were developed to ensure long-term affordability and sustainability.
12 pilot lines were upgraded to produce a wide range of bio-based PUR components and foams, including bio-polyols, lignocellulosic adhesives, functionalized nanofillers, prepregs, soft and rigid foams, and insulation aerogels. These were integrated into a Digital Twin Platform with 22 ad-hoc and 6 generic models for real-time process control and predictive analytics. Some lines were also equipped with inline spectroscopic monitoring systems.
10 demonstrators were validated in operational environments:
- In construction, mock-ups in Spain and Latvia showed improved insulation and energy efficiency.
- In automotive, seat cushions, headrests, and steering wheels met industry standards.
- In furniture and bedding, mattresses, sofas, and chairs demonstrated high comfort, resilience, and sustainability.
Advanced recycling technologies were implemented, including microwave-assisted glycolysis, which achieved up to 53% energy savings. Recyclates were reintegrated into new foam formulations. Nanosafety assessments were conducted across the value chain, and a new standard (CWA 50751:2024) was published to guide data-driven production management.
Sustainability assessments (LCA, LCC, SLCA) confirmed the lower environmental impact and competitive production costs of BIOMAT materials. The project achieved strong visibility: 20 peer-reviewed publications, 65 international events, over 11,000 website visits, and 3 demonstration videos. A strategic exploitation plan was developed, with 11 technologies ready for transfer and a customer database of over 9,000 contacts.
BIOMAT-TB is now positioned as a reference infrastructure for the development and commercialisation of sustainable, nano-enabled bio-based PUR materials in Europe.
The BIOMAT project significantly advanced the development of sustainable polyurethane (PUR) foams and composites by replacing fossil-based inputs with nano-enabled bio-based alternatives. Novel formulations such as bio-polyols, lignocellulosic adhesives, and functionalized nanofillers were successfully scaled up and validated in real-world applications across construction, automotive, and furniture sectors.
Key technological breakthroughs included a 60-fold increase in lignin nano-transformation efficiency via a one-step sono-enzymatic process, integration of inline spectroscopic monitoring and digital twin models for real-time optimisation (reducing offline measurements by 60%), and microwave-assisted recycling of PUR foams, achieving up to 53% energy savings.
By project end, BIOMAT delivered a fully operational Open Innovation Test Bed (BIOMAT-TB) with 12 pilot lines and 8 business services. The Single Entry Point (SEP) platform was validated through two Open Calls, supporting 7 SMEs. Eleven technologies reached market readiness, and 10 demonstrators were validated in operational environments.
The project’s socio-economic and societal impacts are notable. BIOMAT supports the circular economy by enabling PUR reuse and reducing fossil dependency. It contributes to climate goals by lowering CO2 emissions and energy use, enhances SME competitiveness through access to advanced infrastructure, and promotes safer, bio-based materials for indoor environments.
Overall, BIOMAT laid the foundation for a scalable, sustainable, and economically viable ecosystem for bio-based PUR materials, with strong potential for continued exploitation and societal benefit beyond the project’s duration.
Key technological breakthroughs included a 60-fold increase in lignin nano-transformation efficiency via a one-step sono-enzymatic process, integration of inline spectroscopic monitoring and digital twin models for real-time optimisation (reducing offline measurements by 60%), and microwave-assisted recycling of PUR foams, achieving up to 53% energy savings.
By project end, BIOMAT delivered a fully operational Open Innovation Test Bed (BIOMAT-TB) with 12 pilot lines and 8 business services. The Single Entry Point (SEP) platform was validated through two Open Calls, supporting 7 SMEs. Eleven technologies reached market readiness, and 10 demonstrators were validated in operational environments.
The project’s socio-economic and societal impacts are notable. BIOMAT supports the circular economy by enabling PUR reuse and reducing fossil dependency. It contributes to climate goals by lowering CO2 emissions and energy use, enhances SME competitiveness through access to advanced infrastructure, and promotes safer, bio-based materials for indoor environments.
Overall, BIOMAT laid the foundation for a scalable, sustainable, and economically viable ecosystem for bio-based PUR materials, with strong potential for continued exploitation and societal benefit beyond the project’s duration.