Biochemicals from the Bacterial Factory

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Bayer already markets products based on vegetable oils, sugar and starches, such as polyurethane components for efficient thermal insulation of buildings and refrigerators, for textile coatings as well as for fuel saving lightweight automotive construction concepts. One of the next steps towards even greater sustainability is developing materials based on waste products from plants and wood. Genuine leaps in technology are still needed before that can happen, however.

At present, Bayer scientists do not anticipate that complete replacement of fossil resources to cover all material needs will be possible in the mid- to long-term future. “However, bio-based raw materials do also open the door to entirely new property profiles,” Behnken affirms.

A Bio–Product for a Plastic Precursor

The ball has already been set in motion. In cooperation with bacteria specialists like the Dutch company Reverdia and US enterprise Bioamber, Bayer materials experts have been working on replacing the plastic precursor adipic acid for some time now. The substance is generated from gasoline by-products.

“We use the adipic acid for synthesis of polyurethane, which is ideally suited for products such as insulating material or upholstery foam,” Behnken explains. The first step is to let the adipic acid react with a second monomer, a diol. This creates what is known as a polyester polyol. In turn, this substance is used for the final synthesis of polyurethane, in which polyol is mixed with isocyanate. The two link in seconds to form polyurethane.

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Innovative Biotechnology and Creative Molecular Design

“The disadvantages of this procedure are the production of adipic acid is a multi-step procedure and it consumes a lot of energy,” Behnken elucidates. Innovative biotechnology and creative molecular design. To combat this, another route has been taken. Instead of adipic acid, they are using succinic acid for polyol production. This acid comes from the bacterial factories of companies like Reverdia, where it is produced in large quantities by feeding the miniature biological production plants with corn starch.

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