Bio-sourced Polyols

Polyols are essential building blocks for polyurethanes, coatings, elastomers, and personal care products. Conventionally derived from petroleum-based propylene oxide and ethylene oxide, polyols carry a substantial carbon footprint. With growing demand for low-VOC, recyclable, and bio-based alternatives, polyols derived from natural oils, carbohydrates, lignocellulosic biomass, and even CO₂ are gaining strong traction in industrial materials.

This blog explores how bio-sourced polyols are produced, key commercialization efforts, startups innovating in this space, India’s emerging role, and future outlook.

How Bio-sourced Polyols are Produced

Pathway Overview

• Vegetable Oil-Based Polyols
• Epoxidation and hydroxylation of unsaturated plant oils (e.g., castor, soybean, linseed) produce hydroxyl-rich polyols.
• Example: Castor oil already contains natural hydroxyl groups (monomeric polyol).
• Sugar- and Biomass-Derived Polyols
• Glucose, sorbitol, glycerol, and xylitol are fermented or catalytically converted into branched polyether or polyester polyols.
• Lignin-Derived Polyols
• Lignin is depolymerized and functionalized (e.g., oxyalkylation) to produce aromatic-rich polyols suitable for rigid foams and insulation.
• CO₂-Based Polyols
• Carbon dioxide is copolymerized with epoxides (like ethylene oxide) using catalysts to create polyether carbonate polyols.

Case Study: Cargill’s BiOH® Polyols

Highlights:

• Produces polyols from soybean oil via epoxidation and ring-opening reactions.
• Used in furniture foams, automotive seating, and bedding with 20–50% lower carbon footprint.
• BiOH® polyols replace 15–60% of petro-polyols in commercial polyurethane formulations.

Timeline:

• 2005: Commercial launch of BiOH® polyols.
• 2010: Expansion of production in the US and Brazil.
• 2019–2023: R&D on hybrid polyols using lignin and castor oil blends.
• 2024: Collaboration with mattress and auto OEMs for full bio-based foam systems.

Global Startups Working on Bio-based Polyols

• Econic Technologies (UK)
  Converts CO₂ to polyols using proprietary catalyst tech — reducing oil dependency and embedded carbon.
• Huntsman Advanced Materials (USA)
  Offers soy-based polyols blended into bio-PU insulation and elastomers.
• Polioles Naturales (Mexico)
  Uses palm and jatropha oil to create bio-polyether polyols for adhesives and flexible foams.
• BioBased Technologies (USA)
  Among the first to develop soy-based polyol systems for the commercial mattress and packaging industries.
• Vikas Ecotech (India)
  Exploring bio-polyol chemistry using vegetable oils and recycled waste oil streams.

India’s Position

India has immense raw material potential (castor, soybean, linseed oils, glycerol from biodiesel). While few companies directly commercialize polyols, research at IIT Delhi, IISc, and NCL Pune has made progress in:

• Epoxidized vegetable oil polyols
• Lignin- and sugar-derived polyols for foams
• Polyol–isocyanate systems for insulation and footwear

Commercialization Outlook

Market and Demand

• Global market: $9.2 billion (2024); projected to reach $14.8 billion by 2030
• CAGR: ~7.5%, driven by green building, lightweight automotive, and eco-adhesives sectors

Applications

• Flexible & rigid polyurethane foams
• Sealants, adhesives, and coatings
• Artificial leather and thermoplastic polyurethanes (TPUs)
• Personal care and medical polymers

Key Drivers

• Push for VOC-free materials in construction and automotive
• Plastic bans and circular material mandates
• Rising raw material prices and volatility in fossil-based feedstocks
• Growth in LEED and BREEAM-certified buildings

Challenges to Address

1. Functional Consistency

• Bio-polyols have variable hydroxyl number, molecular weight, and reactivity — affecting polyurethane performance.

2. Compatibility with Isocyanates

• Some bio-polyols require adjustment of NCO:OH ratio and additives to match petro-based performance.

3. Processing Challenges

• Higher viscosity, phase separation risks, and need for modified catalysts during polyurethane production.

4. Feedstock Supply Fluctuation

• Seasonal yield and competing demand from food sectors affect oil prices and availability.

5. Cost Gap

• Bio-polyols are 20–40% more expensive than conventional ones unless mass-produced or blended.

Progress Indicators

• 2000–2005: Soy-based polyols launched by Cargill & Biobased Tech
• 2010–2015: Epoxidized castor oil explored by Indian & Brazilian startups
• 2016–2020: CO₂-based polyols developed by Econic Technologies
• 2021–2023: Blended lignin-polyol foams tested for green insulation
• 2024: Multiple furniture & bedding brands shift to >30% bio-polyol-based foam content.

TRL: 7–8
Bio-polyols are commercially available from vegetable oils and in an advanced piloting stage for lignin- and CO₂-derived variants. Compatibility with PU systems is proven; large-scale adoption depends on cost parity and formulation tailoring.

Conclusion

Bio-sourced polyols are no longer niche—they are becoming a mainstream green chemistry option in coatings, foams, and adhesives. With industrial players like Cargill, BASF, and Econic leading innovation, the polyol sector is shifting toward renewables, backed by carbon regulation and consumer demand.

India, with its castor oil dominance, research strength, and emerging bioeconomy policies, is poised to play a significant role in expanding the bio-polyol market — particularly in construction, packaging, and footwear applications.

Wish to have bio-innovations industry or market research support from specialists for climate & environment? Talk to BioBiz team – Call Muthu at +91-9952910083 or send a note to ask@biobiz.in