Overview

Understanding the Challenge

Plastics are an indispensable part of modern life. These materials are used almost everywhere—from food packaging and medical devices to communication technology and automotive applications. Advanced technologies like lightweight design and electric mobility would be inconceivable without plastics. However, the vast majority of the plastics we use today are derived from fossil resources. This dependence on petroleum-based materials is fundamentally unsustainable: fossil resources are finite, and their extraction and post-use combustion cause severe environmental damage.

The global polyurethane market alone is projected to reach USD 88 billion by 2023, with flexible polyurethane foams used extensively in automotive seat cushions and outdoor equipment. On average, a single car contains 22–24 kg of polyurethane, most of it in the form of molded foam for seats. Currently, the vast majority of polyurethane foam production relies on petroleum-derived polyols, perpetuating dependence on non-renewable resources. Yet industries are actively seeking sustainable alternatives—a shift accelerated by ambitious corporate sustainability commitments and regulatory pressures to reduce carbon footprints.

Overview

Our Mission

Bio2Foam develops a novel, sustainable bio-based polyurethane (Bio-PUR) flexible foam from agricultural waste—specifically sugarcane bagasse—to serve the automotive and outdoor sports industries. This collaborative project between Queensland and Germany transforms agricultural residues into high-value, sustainable materials that can directly replace fossil-based alternatives without compromising quality or safety.

The project brings together complementary expertise: Queensland University of Technology (QUT) and Licella leverage their knowledge of agricultural value-added processing and hydrothermal liquefaction of biomass; Lextra contributes expertise in bio-based polyurethane chemistry; Leibniz Universität Hannover (LUH), in collaboration with industrial partners Grammer and VAUDE, converts bio-derived precursors into ready-to-use flexible Bio-PUR foams.

Overview

Our Goal

To demonstrate the technical feasibility, economic viability, and environmental sustainability of producing commercial-scale bio-based polyurethane flexible foams from sugarcane bagasse that meet or exceed the performance standards of conventional petroleum-derived foams for automotive and outdoor equipment applications.

Overview

Why This Matters

Agricultural waste valorization: Bio2Foam unlocks the economic potential trapped in this agricultural waste.

Reduced carbon footprint: Bio-based polyurethane foams can reduce fossil greenhouse gas emissions compared to conventional petroleum-derived foams.

Market opportunity: This project positions Queensland and German manufacturers to capture market share in the growing bioeconomy.

Bioeconomy development: The project serves as a flagship initiative for Queensland-Germany bioeconomy collaboration, establishing a template for future partnerships and demonstrating how agricultural regions can transition toward circular economy principles and higher-value manufacturing.

Work Package 1

Project Coordination & Communication

Objective: Ensure successful project coordination and effective communication of results to all stakeholders.

This work package manages all administrative and communication activities across the distributed international partnership.

Work Package 2

Sustainability Assessment & Techno-Economic Analysis

Objective: Comprehensively assess the environmental, social, and economic sustainability of Bio-PUR compared to fossil-based benchmark materials.

Sustainability assessment is not an afterthought—it is central to Bio2Foam's innovation strategy.

This integrated sustainability approach ensures that Bio2Foam delivers genuine environmental benefits, not merely greenwashing.

Work Package 3

Raw Material Processing – Sugarcane Bagasse to Bio-Oil

Objective: Convert sugarcane bagasse and agricultural residues into crude bio-polyol using hydrothermal liquefaction (HTL) technology.

Licella operates the specialized hydrothermal liquefaction facilities required for this transformation.

Work Package 4

Bio-Oil Fractionation, Characterization & Functionalization

Objective: Transform crude bio-polyols into platform intermediates with enhanced properties suitable for polyurethane foam production.

This work package refines the raw bio-oil through systematic characterization and modification.

Work Package 5

Bio-PUR Production & Material Testing

Objective: Develop Bio-PUR chemistry and flexible foam formulations meeting automotive and outdoor sports industry performance standards.

Grammer operates specialized polyurethane technical centers where foam chemistry is optimized.

Work Package 6

Prototype Development for Industrial Application

Objective: Develop and validate first-generation prototypes demonstrating Bio-PUR feasibility in real-world automotive and outdoor equipment applications.

Building on optimized foam formulations, this work package transitions from laboratory-scale development to prototype-level demonstration:

Work Package 7

Circular Economy – Recycling of Bio-PUR

Objective: Establish pathways for end-of-life recovery and recycling of Bio-PUR foams, closing the circular economy loop.

True sustainability requires consideration of product end-of-life. This work package investigates both chemical and mechanical recycling routes. This work package ensures that Bio2Foam delivers not just a sustainable product, but a sustainable system aligned with circular economy principles.