POLYMEER recently took part in the BIOPOLY Cluster webinar “From Waste to Performance: Designing Bio-Based Polymers for Real Applications”, organised in collaboration with the BIOPYRANIA and POLYMERS-5B projects. This online event brought together leading experts from the projects to discuss the advancement of bio-based polymers derived from waste towards real industrial applications.
The session included project presentations by the coordinators and technical presentations by project partners on various types of feedstock, ranging from brewer’s spent grain (BSG) to wood-based biomass. POLYMEER was represented by Assunta Marrocchi, who outlined the project’s vision of transforming BSG into innovative bio-based polymers, Fabrizio Sarasini, who presented on how BSG can be used to create functional materials, and Frederik Wurm, who explained how novel bio-based and biodegradable polymers can be developed with environment-specific biodegradation properties.
The webinar also featured a panel discussion where experts delved into critical topics such as technical specifications and constraints, feedstock availability, regulatory frameworks, and the future of bioplastics. You can find a summary of their discussion below, and the full webinar recording here.
Can bio-based polymers match high-performance specifications?
Frederik Wurm (University of Twente) and Fabrizio Sarasini (Sapienza University of Rome)
The ability of bio-based polymers to meet high-performance requirements depends largely on the specific application and performance criteria. “High performance” is not a fixed concept, but varies according to the intended use of the material.
In certain areas, bio-based polymers have already demonstrated their strong capabilities. For instance, rigid materials can achieve high glass transition temperatures while remaining recycleable, making them suitable for applications such as rigid packaging. In these contexts, their performance can be comparable to that of conventional, fossil-based plastics.
However, challenges remain when moving into more demanding sectors such as automotive, aerospace, and high-temperature electronics. Bio-based polymers often face limitations in these applications due to lower thermal stability, high sensitivity to moisture, and processing constraints. Long-term durability and stability are also areas that are still under development.
Biodegradability introduces further complexity. Materials designed to break down at the end of their life cycle may struggle to maintain the strong, stable bonds required for high-performance use. However, emerging approaches, such as fungal degradation, offer promising alternatives.
Overall, bio-based polymers can already meet high-performance specifications in certain areas, and ongoing research is rapidly expanding their capabilities. Continued advances in material design and processing are expected to make these polymers viable for an increasingly broad range of high-performance applications.
How do you deal with feedstock variability?
Assunta Marrocchi (University of Perugia) and Merylin Kurst (Fibenol)
Variability in feedstock is a fundamental challenge when working with bio-based resources, as their composition can vary significantly depending on origin, processing conditions and seasonal factors. Rather than attempting to eliminate this variability entirely, different approaches can be adopted to manage and control it effectively.
From the POLYMEER perspective, where BSG is used as the primary feedstock, variability is an inherent characteristic. Differences in raw materials and brewing processes directly influence its composition. Therefore, the strategy is to work with this variability rather than against it. This begins with a thorough characterisation of the feedstock, followed by its fractionation into key components such as cellulose, hemicellulose and lignin. By isolating these fractions, more controlled and predictable material systems can be operated. In parallel, robust formulation and processing strategies are developed to tolerate variations in composition and ensure consistent performance. In this context, flexibility is essential. Rather than treating variability as a flaw to be eliminated, it should be recognised as an intrinsic condition of bio-based systems that must be accommodated through smart design.
A complementary approach can be seen in industrial processes such as those developed by Fibenol. Here, variability is addressed through highly controlled processing at an early stage. Advanced process control systems monitor multiple quality parameters, paying particular attention given to key compositional elements such as C5 sugars, which are actively regulated during pretreatment. Other aspects, such as C6 conversion, are optimised through precise enzyme dosing. In terms of raw materials, both round wood and plywood residues can be used, although plywood residues are preferred as they are consistently dry and come from the most stable part of the wood. In Estonia alone, around 80,000–100,000 tonnes of plywood residues are available each year, so supply is not a limiting factor. The process also relies on empirical control and a residence time of around 30 minutes to maintain consistency.
What are the biggest technical bottlenecks?
Miķelis Kirpļuks (Latvian State Institute of Wood Chemistry) and Merylin Kurst
One of the main challenges identified is the transition from laboratory-scale research to industrial deployment. Increasing the Technology Readiness Level (TRL) remains a significant bottleneck, as bio-based technologies require scaling up and undergo industrial optimisation to become commercially viable. This is particularly challenging given that the petrochemical industry has benefited from decades of refinement and optimisation. In order to compete, bio-based solutions require continued investment, pilot validation and large-scale demonstration. This is why EU funding is increasingly supporting projects operating at higher TRL levels.
From an industrial perspective, the intrinsic complexity of bio-based feedstocks, particularly wood, also poses major technical challenges. Unlike uniform petrochemical inputs, biomass cannot be perfectly separated into its individual components. Consequently, residual chemical reactions may occur during processing, which could affect both material performance and equipment. For example, certain streams, such as C5 fractions, may precipitate and cause blockages in pipelines.
This complexity means that equipment must be adapted to handle bio-based materials. Additional monitoring, process control and operational adjustments are therefore required to ensure stability, efficiency and reliability throughout the production chain.
What regulatory frameworks, standards, and incentives are needed to support the adoption of bio-based polymers while ensuring they meet safety, performance, and end-of-life requirements?
Fabrizio Sarasini and Katrien Bernaerts (Maastricht University)
One key issue that has been identified is the lack of clarity and consistency in the definition of bio-based materials. The terms ‘bio-based’, ‘biodegradable’ and ‘compostable’ are often used interchangeably, despite referring to different properties. This confusion can lead to misleading claims, greenwashing, and incorrect disposal practices. Clear, harmonised definitions and application-specific rules are therefore essential to ensure that materials are used only where they provide genuine environmental benefits.
Another challenge lies in the fragmentation of existing standards. While there are established frameworks for aspects such as compostability, bio-based content and soil biodegradability, these are not always aligned across different standardisation bodies, such as ISO and ASTM, or across regions. Furthermore, important aspects such as long-term stability and performance over time remain insufficiently addressed. To provide clearer guidance for both industry and end users, it is necessary to expand and harmonise standards, including those covering a wider range of degradation environments, such as marine conditions.
From a policy perspective, there is also a strong need to integrate life cycle assessment more systematically into regulatory frameworks. The fact that a material is derived from renewable resources does not automatically guarantee environmental benefits. A full life cycle perspective is required to assess its overall impact, from production to end of life, in order to support informed decision-making.
Safety considerations must also extend beyond the material itself. While existing frameworks, such as REACH, provide a solid basis, additional attention is needed for degradation intermediates and potential impurities present in biomass or introduced during biorefinery processes. This is particularly relevant for biodegradable polymers, where breakdown products may have environmental or health implications.
Finally, enabling the large-scale adoption of bio-based polymers also requires supportive infrastructure and investment. It is essential to expand industrial composting and recycling systems is essential to ensure that these materials can be properly managed at the end of their life, thereby reinforcing their environmental value and facilitating their uptake in the market.
What needs to happen in the next 5 years?
All speakers
Several priorities were identified to accelerate the development and adoption of bio-based polymers. From a policy perspective, stronger economic signals are required to rebalance the current system. This includes stopping subsidies for the petrochemical industry and introducing more robust carbon pricing mechanisms that reflect the long-term environmental costs of emissions. Without properly accounting for these externalities, bio-based solutions will continue to compete on an uneven playing field.
Continued investment in bio-based materials is also essential, as is a willingness within the research community to explore new polymer structures. Rather than replicating conventional fossil-based plastics, bio-based innovation offers the opportunity to develop alternative materials with distinct and potentially superior properties.
A key design principle that was highlighted is the need to consider the end of the product’s life from the outset. Future materials should not only be bio-based, but also recyclable or biodegradable to address multiple sustainability targets simultaneously. This also implies moving beyond drop-in solutions and accepting that existing industrial processes may need to evolve to accommodate new materials.
Another critical step is expanding the range of feedstocks. Greater diversification into non-food biomass sources is required to ensure that these resources are available on an industrial scale and can support the development of truly novel materials, rather than simply replacing existing ones.
Collaboration across the entire value chain was also emphasised as a prerequisite for success. Biomass suppliers, chemical companies, material producers and end users must work together to align innovation, production, and market uptake.
Ultimately, the transition will depend on industries’ willingness to rethink product design and manufacturing processes. Bio-based materials have inherent properties, such as feedstock variability, which must be considered during product development. This shift requires not only technological innovation, but also a broader change in mindset across sectors.
