Bio-Based Alternative Materials

The Carbon Cell is a rigid black foam that offers a plastic-free alternative to expanded polystyrene. The material is made from biochar derived from crop waste combined with bio-based polymers that form small pellets. These pellets are expanded with standard polystyrene equipment into a closed-cell foam that delivers similar protective and insulating performance.

At the end of life, the natural polymer binder breaks down in home composting conditions and leaves only biochar in the soil. For each kilogram of foam produced, an estimated two kilograms of carbon are locked away, giving the material a carbon-negative profile. The company is preparing pilot production focused on packaging and building insulation while also testing versions for acoustic panels, interior products, thermal packaging and lightweight composites for industries that currently rely on petrochemical foam.

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