The bioeconomy and its role in mitigating climate change 

Measuring impact of sustainable practices is key to driving effective change. From fashion to furniture, from the clothes we wear to the cars we drive, producing consumer goods results in billions of tonnes of GHG (greenhouse gas) emissions – contributing to climate change. Globally the footwear industry produces 700 megatons of CO2eq of GHG emissions every year, up to 40% of the emissions are attributed to raw materials manufacturing and extraction.[1] 

Part of the solution is transitioning to a plant or bio-based economy.  

The bioeconomy can be defined as using renewable biobased resources sustainably to produce food, energy and goods. It allows industries to tap into biomass available from agricultural, forestry feedstocks and waste streams that are critical to achieving a net-zero, sustainable future.  

The power of plants 

Plants are one of the most abundant renewable resources on earth. Nature produces more plant matter in one day than the sum of all the petrochemistry-based materials produced globally per year.[2] Plant-based chemistry is comparable to petrochemicals without the negative impact, plants have emerged as a sustainable alternative such as coconut husk, ground stone fruit pits or lignin. 

The impact of renewable plant-based materials on the environment is far less compared to oil-derived counterparts. By conducting a life cycle analysis, Evoco is able to measure the impact of its plant-based material technology, FATES®, from cradle to gate.  

The results are clear, FATES® reduces GHG emissions at the source by up to 70%; using plant-based raw materials results in a substantial step change. 

FATES® was designed to be feedstock agnostic and adapt to local plant feedstocks across the globe 

FATES® is feedstock agnostic material technology, leveraging raw materials derived from a variety of plant by-products. The technology works with a variety of inputs from agricultural, forestry, by-products and waste. We can adapt to a variety of first and second feedstocks, depending on local supply chains. 

Our feedstock today & regenerative farming  

FATES® current feedstock includes field corn. Field corn widely available, and sustainably cultivated in the North American supply chain.  Our raw material does not compete with the food supply. Our technology uses the low-calorie starch by-products leftover (something humans cannot consume) after the corn is processed for animal feed and human consumption. This Ensures that no potential food source or land is diverted to non-food requirements. Currently dedicated arable land for biopolymers is 0.015% and is estimated to increase to 0.058% in 2026. This figure is still less than 0.1% of total arable land and equates to 0.004% of the land use for food & feed.[3] 

The history behind polyurethane  

Polyurethane (PU) was discovered in the 1930s as an alternative to rubber, and is highly regarded for its durable, flexible, and chemical resistance properties.  
In the 1950s, polyurethane foam (PU foam) was popularized and found in almost all aspects of our daily lives. From footwear, apparel, furniture, bedding, and automobiles, you are probably sitting on, sleeping on, driving in, or wearing PU foam.  

How polyurethane foam is made 

It starts with a few key chemicals mixed:  

Polyols + Additives + Isocyanate = urethane bonds.  

This reaction creates the polyurethane foam that we all love for its comfort and performance.  

Today, PU foams can be made conventionally from oil-derived chemicals (petrochemistry) or from plants. Both oil and plant-based PU foams go through a similar production process, but it is the development and raw materials that make plant-based polyurethane foams more sustainable and allow for high performance properties.  

Where conventional oil-based polyurethane foam comes from?

Simply put, oil-based PU is made from petrochemicals or fossil fuels, mainly crude oil. These non-renewable resources have a high impact on the environment and use toxic materials that pollute the soil and degrade into microplastics.  

How bio-based polyurethane foam is disrupting the foam industry

FATES®, Evoco’s plant-based foam, starts by extracting glucose, starches, and other building blocks from plants. We harness the basic components from these plants and use them to develop plant-based chemistry, resulting in a diverse range of formulas that meet a wide variety of technical specifications such as density, tensile strength, elongation and more. FATES eco-foam is made from up to 80% plants, reducing GHGs (greenhouse gas) emission by up to 70% in comparison to conventional oi-based PU foam This positive environmental impact is substantiated by a third-party verified, cradle–to–gate LCA (Life Cycle Assessment) model. In addition, FATES does not use heavy metal catalysts, and is shown to degrade back into the earth, creating a circular material.