New innovation eliminates fossil carbon in polyurethanes, setting the stage for truly circular materials
SAN DIEGO, Aug. 4, 2025 /PRNewswire/ — 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.
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.
Learn more at www.algenesislabs.com.
About Algenesis Labs
Algenesis leads the way in sustainable materials, using cutting-edge science to deliver durable, accessible, and biodegradable plant-based polymers that empower customers to reduce plastic pollution. The company’s Soleic® materials enable real-world circularity and sustainable design across industries.
Press Contact:
Sandra Watts, Director of Marketing
Algenesis Corporation
399064@email4pr.com
858-344-9805
www.algenesislabs.com
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SOURCE Algenesis Labs
