Technology · Biochemistry & industrial biotech / Polymers & materials
Bio-based polyols & biopolyurethanes
Renewable hydroxyl-functional building blocks from vegetable oils, lignin and cashew nutshell liquid that replace petrochemical polyols and isocyanates in flexible foams, coatings, TPU and elastomers.
1 · What it gives
Bio-based polyols are hydroxyl-functional intermediates synthesised by introducing –OH groups into the triglycerides of vegetable oils (soybean, castor, rapeseed, linseed) or into alternative aromatic feedstocks (lignin, cashew nutshell liquid). Reacted with (bio-)isocyanates, they yield biopolyurethanes — flexible and rigid foams, thermoplastic polyurethanes (TPU), coatings, adhesives and elastomers — that are 30–100% bio-derived versus their petrochemical analogues. Natural-oil polyol lines such as BASF’s Sovermol typically carry 80–100% bio-content, while bio-PDO chain extenders cut cradle-to-gate greenhouse-gas emissions by up to 86% versus fossil PDO. The global polyurethane market is projected to exceed $90 bn through 2026, and the US soy-polyol segment alone is forecast to grow from $487.6 M (2026) to $1,033 M (2035) at an 8.70% CAGR — so even partial bio-content substitution moves multi-billion-dollar procurement volumes. Hydroxyl values are tuned to 50–240 mg KOH/g to match flexible-foam, rigid-insulation or coating duties.
The key directions of bio-based polyols and biopolyurethanes are:
- Vegetable-oil polyols (Soybean / Castor / Rapeseed / UCO Polyols): epoxidation of unsaturated fatty acids followed by acid-catalysed ring-opening with alcohols or diols — the workhorse route, supplying >80%-bio-content polyols for flexible foams, mattresses and automotive seating.
- Bio-based diisocyanates (Bio-PDI): precision fermentation of lysine to 1,5-pentanediamine, then phosgene-free conversion to pentamethylene diisocyanate — the breakthrough that removes the last 100%-petrochemical half of a polyurethane, pioneered at 50 kt/yr scale in China.
- Non-isocyanate polyurethanes (NIPU): reaction of cyclic carbonates (from epoxidised oils + captured CO2) with bio-based diamines, fully eliminating toxic phosgene and isocyanate chemistry — the EU-led response to ECHA isocyanate restrictions.
- Lignin & CNSL polyols (Aromatic Bio-Polyols): partial hydrolysis of kraft/organosolv lignin or ethoxylation of cardanol from cashew nutshell liquid, delivering rigid aromatic backbones with inherent flame resistance and extreme hydrophobicity for marine coatings.
Sectoral value chain#
[vegetable oils / lignin / CNSL] ──> [epoxidation + ring-opening] ──> [bio-polyols (B2B)]
│
(OH value 50–240 mg KOH/g)
│
▼
[bio-PU foam / TPU / coating] <─── [reaction with bio-PDI / NIPU] <─────┘
Value chain levels#
| Level | Description | Key inputs/outputs |
|---|---|---|
| Feedstock origination | soybean, castor, rapeseed, UCO, lignin, CNSL sourcing | In: oilseeds, castor beans, waste oils. Out: refined triglycerides. |
| Epoxidation | peracid oxidation of C=C bonds to oxirane rings | In: vegetable oil, H2O2, formic acid, resin. Out: epoxidised oil. |
| Ring-opening / polyol synthesis | acid-catalysed ring-opening to install –OH groups | In: epoxide, alcohol/diol, catalyst. Out: bio-polyol (set OH value). |
| Bio-isocyanate / NIPU precursor | fermented pentanediamine → PDI, or cyclic carbonate | In: lysine, sugars, CO2, diamines. Out: bio-PDI / cyclic carbonate. |
| PU reaction / foaming | high-pressure mix of polyol + isocyanate, or NIPU | In: bio-polyol, bio-PDI, catalysts. Out: foam / elastomer / TPU. |
| Certification & QA | ASTM D6866 C14, ISCC PLUS mass balance, CertiPUR | In: cured articles, test rigs. Out: certified bio-PU product. |
Cross-cutting technologies of the sector:
- Epoxidation + ring-opening chemistry (Epoxidation + Ring-Opening): peracid generation in situ from H2O2 and carboxylic acid over a cation-exchange resin, followed by acid-catalysed oxirane opening — controls OH value and functionality.
- Bio-PDO fermentation (Bio-PDO Fermentation): precision fermentation of corn-dextrose glucose to 1,3-propanediol (Susterra/Zemea), used as a chain extender and polytrimethylene ether glycol (PO3G) polyol.
- ISCC PLUS mass balance (ISCC PLUS Mass Balance): certified book-and-claim accounting that allocates renewable feedstock to bio-attributed PU grades (Desmopan EC, Sovermol) in existing asset bases.
2 · What it replaces 2 · matched by industry
| D1E– | Bio-based binders and bio-solvents instead of petrochemical resins and VOC solvent systems in paints and coatings Replaces: Petro-derived alkyd/acrylic binders; volatile organic solvent systems (white spirit, toluene, xylene) in solvent-borne paints; part of … | CHEM |
| D1E– | Paint and coating preservation with less isothiazolinone biocide — formulation hygiene, low-water-activity and bio-based boosters Replaces: Routine isothiazolinone loading (MIT/CMIT/OIT/BIT) as in-can preservative and film antifungal in waterborne paints | CHEM |
3 · How to implement 6 steps
- 1Oil purification and input QCPurification & downstreamTesting & analyticsSoybean oil is filtered and bleached with activated clay; the iodine value must exceed 120 g I2/100 g (unsaturation) and the acid value stay below 1 mg KOH/g to protect downstream catalysts.Who can do this step matched automaticallyEsco Aster Singapore✓ ISO 9001 5,000 L industrial scale“Adherent cell culture and downstream processing: commercialized Tide Motion bioreactor platform (MiniTide to TideXcell) with closed automated cell harvesting and single-use …”✓ ISO 9001 500 m3“Development of robust, scalable fermentation and downstream processing (production and recovery/yield optimization).”
- 2Epoxidation of triglyceridesOil, formic acid and a cation-exchange resin are charged; 50% hydrogen peroxide is dosed over 3–4 h at 60°C with jacket cooling — the exotherm is held below 85°C to avoid gel-forming polymerisation.
- 3Wash, neutralisation and vacuum dryingPurification & downstreamThe resin is filtered out, the epoxidised oil is washed with deionised water and neutralised, then vacuum-dried at 90°C / 50 mbar to water content below 0.05%.Who can do this step matched automaticallyEsco Aster Singapore✓ ISO 9001 5,000 L industrial scale“Adherent cell culture and downstream processing: commercialized Tide Motion bioreactor platform (MiniTide to TideXcell) with closed automated cell harvesting and single-use …”✓ ISO 9001 500 m3“Development of robust, scalable fermentation and downstream processing (production and recovery/yield optimization).”Algal Bio Japanindustrial scale“・Equipped with comprehensive downstream processing capabilities (Concentration, sterilization, and drying)”ScaleUp Bio Singapore10,000 L pilot scale“Core capabilities span pilot-industrial fermentation and downstream unit operations (centrifugation, TFF, chromatography, solvent extraction, spray/freeze drying) with cGMP …”
- 4Ring-opening to polyolThe epoxide is reacted with methanol or ethylene glycol over phosphoric acid at 120°C for 4 h; excess alcohol is vacuum-stripped and the polyol is tuned to a hydroxyl value of ~150 mg KOH/g.
- 5A-component preparation and foamingFormulation & blendingThe bio-polyol is blended with water (blowing agent) and amine catalyst, then mixed with bio-PDI isocyanate in a 150-bar high-pressure mix head and dispensed into a 50°C mould — start time 10–15 s, gel time 40–60 s.Who can do this step matched automaticallyIndia Glycols (NSE) India✓ ISO 9001 7,500 MT/ industrial scale“Recent expansions and new facilities across процесses: MEG production growth (up to 200,000 MTPA), EO purification, ethoxylate, sulphation, formulation plants, and …”Rossari Biotech (NSE) India✓ ISO 9001 industrial scale“The company also announced a new greenfield blending facility in Thailand to boost Southeast Asia operations and smarter capacity utilization across its HPPC, TSC, and AHN …”✓ ISO 9001 500 m3“This is a satellite blending, mixing and formulation facility, located at Vashind near Shahapur and dedicated to the company’s Animal Nutrition business.”Thai Wah Thailand10,000 tons“Premix Factory in Jiaxing, China, to develop and produce premixes for bakery, dim sum, coatings, and texturizers, with 10,000 tons annual capacity, signaling a shift toward …”500,000 tons pilot scale“It refines sugar (including refined white sugar, golden brown sugar, fine granulated sugar and invert sugar syrup), produces bio-based chemicals/biotech outputs (alcohol, …”
- 6Curing and QA/QCTesting & analyticsThe moulded foam is demoulded after 5 min and cured 24 h at room temperature; ASTM D3574 covers density, tensile strength and compression set, and fluctuation-chamber testing confirms no residual amine or isocyanate emissions before the bio-PU article ships.Who can do this step matched automaticallyEsco Aster Singapore✓ ISO 9001 5,000 L industrial scale“Esco Aster (Singapore) is a cGMP contract research, development and manufacturing organization (CRDMO/CDMO) and bioinnovation venture accelerator that helps clients and …”industrial scale“ProBio: A global CRDMO (contract research, development, and manufacturing organization) providing end-to-end solutions for biologics and cell and gene therapy (CGT).”
4 · Who delivers
Matched suppliers (matched automatically)
| Cathay Biotech 凯赛生物 (SSE 688065) | China | Producer | active |
| Shandong Bailong Chuangyuan (BLD Bio) | China | Research / RTO | active |
| Toray | Japan | Producer | active |
| COFCO Biotechnology 中粮科技 (SZ 000930) | China | Research / RTO | active |
| Novamont | Italy | Research / RTO | active |
Listed suppliers
Cathay Biotech 凯赛生物 (SSE 688065)
In the services and supply catalogue 2 · paid service
Biopolymers & materials · Contract manufacturing (CMO/CDMO/toll)
Leading companies and institutes (from the brief)
| Company / Institute | Country | Key products / platforms | Tech features | Status 2026 |
|---|---|---|---|---|
| Cargill | 🇺🇸 USA | BiOH soy polyols | epoxidised soybean oil, flexible foam | Commercial |
| CovationBio PDO | 🇺🇸 USA | Susterra / Zemea bio-PDO | 77,000 t/yr, 86% lower CO2 | Commercial |
| Covestro | 🇩🇪 Germany | Desmopan EC bio-TPU, bio-aniline MDI | up to 60% biomass, Bio4PURConti | Commercial |
| BASF | 🇩🇪 Germany | Sovermol natural-oil polyols | 80–100% bio-content, castor/rapeseed | Commercial |
| Cathay Biotech | 🇨🇳 China | bio-pentanediamine, long-chain diacids | 50 kt/yr PDI precursor, 688065.SH | Commercial |
| Jayant Agro-Organics | 🇮🇳 India | castor bio-polyols (Vithal Castor Polyols) | 90% VCPL stake (2026), NSE:JAYAGROGN | Commercial |
5 · Rules & route to market
Route into Russia / EAEU: CHEM · Minpromtorg (registration) / Rospotrebnadzor (notification of new substances)
state registration ~10-15 working days after expert assessment; new substances need notification
Information, not legal advice — confirm the procedure for your product. (2026-10-06)
state registration ~10-15 working days after expert assessment; new substances need notification
Information, not legal advice — confirm the procedure for your product. (2026-10-06)
United States
The US anchors the soy-polyol segment, leveraging the Midwest soybean crushing belt and federal procurement preference under USDA BioPreferred.
soy-polyol leadership, bio-PDO chain extenders, automotive + bedding demand#
- Cargill BiOH polyols: epoxidised/hydroxylated soybean-oil polyols sold into mattress and automotive flexible foam (Room & Board upholstery, Ford seating), replacing a portion of petrochemical polyol.
- CovationBio PDO (ex–DuPont Tate & Lyle): 77,000 t/yr bio-PDO from regenerative Midwestern corn, processed in Loudon, TN — 86% lower carbon footprint (4.41 kg CO2 eq) than fossil PDO, 20 years in market.
- US soy-polyol market: $487.6 M in 2026, forecast to $1,033 M by 2035 at 8.70% CAGR, with EPA TSCA Section 5 pathways and USDA BioPreferred accelerating reformulation.
European Union
The EU leads on non-isocyanate polyurethanes (NIPU) and circular feedstocks, driven by ECHA restrictions on toxic isocyanates in construction foams and coatings.
NIPU R&D, UCO/animal-fat feedstocks, ISCC PLUS + OEKO-TEX certification#
- Covestro bio-aniline + MDI: the €8.4 M EU-funded Bio4PURConti project (June 2026) targets the world’s first continuous bio-based aniline process for MDI, cutting up to ~20 Mt/yr of global fossil-aniline CO2; Desmopan EC TPU carries up to 60% biomass carbon (>20% lower footprint).
- BASF Sovermol polyols: natural-oil polyols (rapeseed/castor) at 80–100% bio-content for solvent-free industrial, marine and wind-power coatings.
- Circular feedstocks: used cooking oil (UCO) and technical animal fats epoxidised into polyols, avoiding food-vs-land competition; OEKO-TEX Standard 100 and CertiPUR govern eco-leather and furniture-foam emissions.
China
China is the global hub for bio-based diisocyanates, converting castor oil and fermented diamines into the world’s first fully bio-based PU elastomers and foams.
bio-PDI breakthrough, castor-oil mega-plants, state green-chemistry subsidies#
- Cathay Biotech (688065.SH): precision-ferments lysine to bio-based pentanediamine (50 kt/yr, the PDI precursor) and long-chain dicarboxylic acids (115 kt/yr, DC10–DC18), plus bio-polyamides (100 kt/yr); 2025 Q3 revenue RMB 2.545 bn (+14.9%), 494 patents.
- Castor-oil polyol plants: large Zhejiang and Jiangsu facilities modify castor oil into polyols for the global sustainable-footwear sole supply chain.
- State subsidies: green-chemistry projects subsidised under national carbon-intensity-of-industry programmes, with GB indoor-air-quality standards tightening purity specs.
6 · Money: tenders & grants
| Grant | Capacity Building Grants for Non-Land-Grant Colleges of Agriculture Program National Institute of Food and Agriculture · United States | Nov 10, 2026 25 days |
| Grant | Capacity building for extending product lifecycles through repair and refurbishment European Commission · EU | Sep 22, 2027 341 days |
| Grant | Carbon farming innovation and scale-up European Commission · EU | Sep 23, 2027 342 days |
7 · Tech stack & innovations
The stack couples oleochemical polyol synthesis with a new generation of bio-based hard-segment monomers and non-isocyanate routes.
- Epoxidation + ring-opening route (Epoxidation + Ring-Opening):
- peracetic/formic acid generated in situ from 50% H2O2 over a cation-exchange resin at 50–70°C opens C=C bonds into oxiranes.
- ring-opening with methanol gives flexible, low-functionality polyols; ethylene glycol or glycerol raises functionality for rigid foams — OH value targeted to 150 mg KOH/g.
- Bio-PDO and bio-PDI hard segments (Bio-PDO / Bio-PDI):
- corn-dextrose fermentation to 1,3-propanediol (PO3G polyol / chain extender), and lysine fermentation to 1,5-pentanediamine converted to pentamethylene diisocyanate.
- case: Cathay Biotech’s 50 kt/yr pentanediamine enables 100%-bio-derived PU elastomers; CovationBio PDO cuts GHG 69% and non-renewable energy 60%.
- Non-isocyanate polyurethanes (NIPU):
- CO2-added cyclic carbonates from epoxidised oils react with bio-based diamines, yielding hydroxy-PU with no phosgene or free isocyanate.
- residual –OH groups improve adhesion to metal and glass, suiting EU construction and coating uses under ECHA limits.
Sources 7 · 0 independent · 7 producer sites
Producers' own sites 7
- Cargill producer checked 2026-05-26 · link not kept
- Dupont tate lyle producer checked 2026-06-18 · link not kept
- Emery oleochemicals producer checked 2026-06-24 · link not kept
- Covestro producer checked 2026-06-22 · link not kept
- Basf producer checked 2026-04-27 · link not kept
- Cathay biotech producer checked 2026-06-29 · link not kept
- Jayant agro organics producer checked 2026-05-29 · link not kept