Biobased Propylene Glycol

Propylene glycol (PG) is a versatile, water-soluble alcohol widely used in cosmetics, food, pharmaceuticals, plastics, and deicing fluids. Traditionally derived from petroleum-based propylene oxide, PG’s fossil origin and associated emissions have led to a shift toward bio-based production using glycerol, glucose, or sorbitol.

This blog outlines how bio-based PG is made, presents two major case studies, highlights active companies, evaluates commercialization status, and explores challenges and future outlook.

Bio-based Propylene Glycol Production Pathway

1. Feedstock Options

• Biodiesel-derived Crude Glycerol (widely used, low-cost)
• Glucose, Sorbitol, and Lactose from biomass
• Cellulosic Sugars (early-stage, under R&D)

2. Conversion Routes

• Hydrogenolysis of Glycerol
• Catalysts: Cu-ZnO, Ru, Ni-based
• Converts glycerol → 1,2-propanediol (PG)
• Fermentation & Biocatalysis (emerging)
• Engineered microbes convert sugars to lactic acid → PG
• Lower temperature/pressure vs chemical route

3. Purification

• Fractional distillation or adsorption
• Food/pharma-grade PG (≥99.5% purity) requires multiple polishing steps

Case Study 1: ADM & Cargill Joint Venture – Glycerin to PG

ADM-Cargill established a JV in 2007 to commercialize PG from biodiesel-derived glycerol via hydrogenolysis.

Highlights:

• One of the first commercial-scale plants for bio-PG
• Feedstock: Crude glycerin from ADM’s biodiesel units
• Reduced GHG emissions by ~61% compared to petro-PG
• Served food, pharma, and industrial markets

Timeline:

• 2007: JV formed; technology licensed from Ashland’s Susterra™
• 2010: 100,000-ton/year plant started in Decatur, IL
• 2013–2016: Expanded into personal care and industrial coolant sectors
• 2020–2023: ADM continued PG operations post JV phase-out

Case Study 2: Oleon (Avril Group) – European Bio-PG Initiative

Oleon produces bio-PG using vegetable oil–derived glycerol, integrating with its fatty acid production operations in Europe.

Highlights:

• Integrated value chain: oleochemicals + biodiesel + PG
• Applied circular economy by valorizing glycerol side-streams
• Developed pharma-grade bio-PG for cosmetics and life sciences
• Expansion aligned with EU bioeconomy targets

   

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Timeline:

• 2015: Launch of PG production from waste glycerol
• 2018: Introduced pharma-grade PG portfolio
• 2020–2022: Capacity expansion to meet EU demand
• 2024: Evaluating entry into Asian markets via licensing partners

Global Startups & Projects

Commercialization Outlook

Market Size & Demand

• Global PG market (2024): ~$4.1 billion
• Projected (2032): ~$6.3 billion (CAGR ~5.5%)
• Bio-based PG: ~10–15% of global share (expected to grow with glycerol oversupply)

Applications:

• Food: Emulsifier, carrier
• Cosmetics: Humectant, solvent
• Deicing fluids and antifreeze
• Unsaturated polyester resins

Growth Drivers:

• Surplus glycerol from biodiesel & oleochemical sectors
• Demand for non-toxic, food-grade alternatives
• Favorable EU REACH and US FDA regulatory acceptance
• ESG and carbon labeling in personal care and food packaging

Key Challenges

1. Feedstock Variability
• Crude glycerol quality depends on biodiesel process
• Pretreatment needed to avoid catalyst poisoning
2. Catalyst Cost & Stability
• Cu-based catalysts degrade over time; noble metals are expensive
• Fermentation routes not yet cost-competitive
3. Market Penetration vs. Petro-PG
• Bio-PG: ~$2.2–3.5/kg
• Petro-PG: ~$1.5–2.0/kg
• Premium only accepted in cosmetics and pharma, not industrial
4. Scale-Up of Biocatalysis
• Enzyme- and microbe-driven PG production still at lab/pilot stage
• Requires integration with waste-to-value bio-refineries

Progress Indicators

TRL: 8–9

Glycerol hydrogenolysis to PG is fully commercial. Biocatalytic routes (from sugars or lactate) are at TRL 4–5

Conclusion

Bio-based propylene glycol is a proven, scalable green alternative to petrochemical PG. Leading players like ADM and Oleon have already commercialized PG production from biodiesel-derived glycerol, contributing to waste valorization and carbon reduction. With growing demand in pharma, personal care, and eco-industrial sectors, bio-PG is set to expand further—especially if enzymatic and sugar-based routes can overcome technical and economic hurdles.

As bio-refinery integration and feedstock flexibility improve, bio-based PG will play a vital role in reducing petrochemical dependence while supporting the shift to a safer, circular chemicals economy.

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