A consortium of fourteen European parties will be working over the coming years on a new generation of high-performance bio-based plastics based on polylactic acid, better known as PLA. The project, named SUPREME-PILOTS, started in Zaragoza in June 2026 and is funded by the European research program Horizon Europe. Coordination is handled by the Spanish technology center Fundación AITIIP.
PLA is made from renewable raw materials such as corn or sugar beet and has long been considered one of the most promising alternatives to fossil plastics. However, for demanding industrial applications, the material falls short in its standard form: it can be too stiff or brittle, and does not always offer sufficient heat resistance, flexibility, or durability for long-term use.
New building blocks for better properties
The project aims to remove these limitations by combining PLA with other bio-based building blocks, including polyester polyols and bio-based polytetramethylene ether glycol (bio-PTMG). By adjusting the ratios of these components, it should be possible to more precisely control the flexibility, strength, heat resistance, and processability of the final material.
For production, the consortium is focusing on reactive extrusion: a continuous process in which raw materials are simultaneously heated, mixed, and chemically converted. According to the project partners, this method can limit the use of solvents and contribute to less waste, lower energy consumption, and reduced production costs. Artificial intelligence and machine learning are being used to arrive at promising material combinations more quickly, with the aim of shortening the path from laboratory to industrial production.
The project operates according to the European principle of Safe and Sustainable by Design, whereby safety, sustainability, and circularity are taken into account from the design phase onwards, rather than being assessed afterwards.
Four practical applications as a test case
The developed materials are not only evaluated in the laboratory but also validated through four practical applications using various industrial production techniques. Through large-scale 3D printing, the consortium is developing lightweight, foamed sports and protection products such as crash mats and wall protection. Rotational molding is intended to lead to bio-based and recyclable products for public spaces, such as planters. Calendering is being used to create more sustainable, wear-resistant floor coverings for healthcare and sports facilities, among others, and through film production and lamination, the project is developing flexible industrial signage and warning tape as an alternative to PVC.
Circularity runs through the project. Both mechanical and chemical recycling routes are being explored for the developed materials, with the aim of extending their lifespan and reducing waste. The consortium aims for a reduction of more than 35 percent in CO₂ equivalent emissions.
Broad consortium, longer lead time
In addition to Fundación AITIIP, the consortium includes Novamont, FH OÖ Forschungs & Entwicklungs, Fundación GAIKER, Envico Research, Competence Center CHASE, Artigo, Comercial Edizar, Moses Productos, AM3D Metalica, LC Innoway, the Roman standardization organization ASRO, Universidade Nova de Lisboa and the Swiss research institute Empa. This means that the entire value chain is represented: from material development and processing to product development, standardization and sustainability assessment.
The project is currently at the beginning of the implementation phase. In the coming period, the partners will focus on developing and testing new PLA formulations, validating processing routes, and preparing for industrial field tests.
Source: WIT News
Photo: LS Visuals, Adobe Stock
