How Epoxidized Vegetable Oils Are Used to Make Biobased Epoxy Resins
Core Production Steps
- Vegetable Oil Sourcing & Pretreatment
- Common feedstocks include soybean oil, linseed oil, castor oil, and sunflower oil.
- Oils are purified to remove moisture, free fatty acids, and impurities.
- Epoxidation of Double Bonds
- Unsaturated fatty acids in the oil undergo epoxidation using peracids (e.g., performic or peracetic acid) or enzymatic methods.
- This process introduces epoxy groups onto the triglyceride backbone, creating epoxidized vegetable oils (EVOs).
- Curing with Hardeners
- EVOs are mixed with curing agents like anhydrides or amines to form crosslinked thermoset networks.
- Additional modification (e.g., blending with bio-based diluents) can tune viscosity and reactivity.
- Application & Use
- Used in coatings, composites, electronics encapsulation, flooring, adhesives, etc.
Case Study: Cardolite Corporation – CNSL-Based Epoxy Systems
Highlights:
- Developed bio-epoxy systems using cashew nutshell liquid (CNSL) and epoxidized linseed oil.
- Targeted applications in marine coatings, flooring, and adhesives.
- Delivered high bio-content (~70%), strong chemical resistance, and low VOCs.
Timeline & Outcome:
- 2015: CNSL-based epoxy platform introduced.
- 2018: Commercialization in marine and protective coatings.
- 2021: High-performance grades launched for structural adhesives and composites.
- 2023: Expanded portfolio with new curing agents and diluent blends to improve thermal stability.
Global Startups and Innovators
- Cardolite (USA/India) – CNSL and EVO-based epoxy systems for coatings and adhesives.
- Entropy Resins (USA) – Plant-based epoxies for surfboards, sports gear, and composites.
- Greenpoxy by Sicomin (France) – Bio-epoxy resins with up to 55% bio-content.
- MAEKO Resins (Spain) – Epoxidized vegetable oils and lignin-based epoxy blends.
- Polioli SpA (Italy) – Bio-resins and hardeners for sustainable coatings
India’s Position
- India is a global leader in castor oil and CNSL production.
- Companies like Cardolite India and Jayant Agro are actively developing EVO-based resins
- Early adoption seen in floor coatings, panel boards, and wood adhesives.
- Bioepoxies align with India’s push toward green buildings, furniture, and electronic insulation materials.
Commercialization Outlook
Market & Demand
- Global biobased epoxy resin market: ~$1.3 billion (2024); projected CAGR ~6.8%
- Applications:
- Protective and industrial coatings
- Bio-composites in sports, construction
- Electronics encapsulation and adhesives
Key Drivers
- VOC and BPA regulations in EU and North America.
- Growing demand for eco-friendly composites and construction materials.
- Availability of non-edible vegetable oils like castor and linseed in Asia.
Challenges to Address
- Slower cure rates and lower thermal resistance in some EVO-based resins.
- High viscosity requires reactive diluents or formulation tweaks.
- Limited awareness and adoption in mainstream industrial applications.
- Need for standardized bio-content certifications in India.
Progress Indicators
- 2010–2015: R&D and small-scale commercialization by Cardolite and Entropy Resins.
- 2016–2019: Epoxidized soy and linseed oil formulations enter building and flooring sectors.
- 2020: EU eco-labels approve bio-epoxies for green buildings.
- 2022–2023: Indian research institutes conduct pilot trials with CNSL and castor-oil epoxies.
- 2024: Increasing demand from green furniture, electrical insulation, and natural composites.
Globally, epoxidized vegetable oil-based epoxy resins are at TRL 8–9, with commercial use in coatings, adhesives, and composites. In India, TRL ranges from 5–7, with successful lab-to-pilot scale validation and emerging industrial interest.
Conclusion
Biobased epoxy resins made from epoxidized vegetable oils represent a powerful shift toward non-toxic, low-carbon, and renewable alternatives to conventional BPA-based systems. From Cardolite’s CNSL-based epoxies to Greenpoxy in marine applications, these systems are proving that performance and sustainability can go hand-in-hand. With India’s abundant non-edible oil feedstocks and growing green chemistry ecosystem, scaling up production and application of bio-epoxies is well within reach. Future growth hinges on cost optimization, fire safety standards, and strong industry-academia partnerships to unlock their full market potential.
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