New innovation eliminates fossil carbon in polyurethanes, setting the stage for truly circular materials

SAN DIEGO, Aug. 4, 2025 -- Algenesis Labs, a leader in sustainable materials science, today announced the commissioning of our Bio-Iso™ pilot plant, where we now make the world's first 100% biogenic carbon isocyanate that is made from plants—a disruptive innovation in polyurethane chemistry. Unlike traditional isocyanates derived from petroleum and manufactured using highly toxic phosgene, Bio- Iso™ is made from plant-based dicarboxylic acids and manufactured without the use of phosgene. This novel process is both modular and scalable, setting a new benchmark for performance, safety, and sustainability.

Dr. Halloran working on our newest biobased innovation.

A sample of 100% bio-based TPU made with Soleic® polyol and Bio-Iso™, offering a fully renewable alternative to conventional plastics.

For decades, the global plastics industry has been dependent on fossil fuel-based isocyanates, locking manufacturers into a cycle of environmental harm and hazardous processes. Bio-Iso™ breaks that cycle—offering a solution that performs on par with petroleum-based isocyanates while fully eliminating fossil carbon and phosgene from the isocyanate supply chain.

"This isn't just a greener alternative. Bio-Iso™ represents a fundamental shift in how we think about polyurethane production," said Dr. Stephen Mayfield, CEO at Algenesis Labs. "Combined with our Soleic® polyol, Bio-Iso now enables a 100% biobased TPU—validated through ASTM D6866-24 analysis by Beta Analytic—that delivers truly circular, sustainable materials without compromising durability or performance."

Bio-Iso™ is the foundation for a new class of plant-based polyurethanes, enabling manufacturers to align their products with global sustainability goals and meet increasing regulatory and consumer demands for safer, eco-conscious materials.

Algenesis is actively scaling the Bio-Iso™ process at its San Diego facility, and is seeking strategic partners to support global industrial-scale commercialization. These partnerships may include financial, technical, engineering, or operational collaboration. In return, early partners will gain priority access to Bio-Iso materials, options for future volume, and shared leadership in transforming the urethanes industry.

A technical data pack is available, including detailed analytical results and performance data on Soleic® TPU materials made with Bio-Iso™.

Key Benefits of Bio-Iso™:

• 100% Biogenic carbon derived from plants – The carbon in our isocyanates is derived entirely from renewable, plant-based feedstocks
   
• Phosgene-Free Processing – Our green chemistry processes offers safer and more environmentally responsible chemical manufacturing
   
• Lower Carbon Footprint – Significantly reduces greenhouse gas emissions compared to petroleum-based isocyanates
   
• Petroleum-Comparable Performance – High durability and functionality across applications
   
• Circularity-Ready – Enables the design of products that biodegrade at end-of-life without leaving behind persistent microplastics

This launch marks the latest milestone in Algenesis Labs' mission to create sustainable materials that help eliminate microplastic pollution and fossil fuel dependency.

Source: Algenesis