It’s a green light for the industrial production of the innovative bioplastic PLH from Dan*na (Artificial Nature, SL). This bioengineering company, specialising in biomaterials and based at the Parc Científic de Barcelona (PCB), is making the leap to the industrial production of its bioplastic, PLH, a globally patented copolyester that combines sustainability and high performance. After closing a funding round of more than one million euros last year, the company has successfully validated the industrial scale-up to manufacture more than 300 tonnes per year of PLH together with its industrial partner at the Chempark in Leverkusen (Germany), with the objective of entering the consumer and electronics market during 2026.

In 2023, Dan*na obtained the international patent for PLH, a unique bio-based copolyester that has proven excellent mechanical and thermal properties with a higher electrical insulation capacity than conventional petroleum-based polymers such as polypropylene (PP) and polyethylene (PE). This positions it as a competitive alternative, also from an economic point of view, in markets where traditional bioplastics cannot compete. Unlike traditional thermosets, it generates up to 75% less CO₂ emissions. In addition, PLH is a fully biodegradable plastic that follows a natural degradation process into environmentally friendly compounds.

“With the validation of the industrial scale-up and its characterisation, we have confirmed that PLH is a viable alternative to fossil-based engineering plastics. This achievement opens the way to markets where sustainability and high technology go hand in hand,” says Xavier Marin, CEO and founder of Dan*na. The start-up wants to revolutionise the use of plastic in the technology industry by following the principles of green chemistry, a discipline that promotes the creation of safer materials and processes that reduce the use of substances toxic to human health and minimise environmental impact from production to the end of the product’s useful life.

The injection of capital, led by fund manager BeAble Capital and two other investors, has successfully validated the PLH to bring it to market. This copolyester has high-value applications in sectors such as electronics, biomedicine and consumer goods, where it stands out for its strength, stability and versatility in environments that require maximum performance for flexible materials and with a competitive price that guarantees its profitability.

100% bio-based and biodegradable material

Each year, the world generates 51.7 million tonnes of plastic pollution, distributed throughout the planet in the form of microplastics, from the depths of the oceans to the inside of the human body. In an increasingly digitised world, the global production chain continues to rely heavily on fossil fuels. According to a recent study published in Nature Communications, only 9.5% of the plastics produced in 2022 will come from recycled materials.

“Plastics cannot disappear due to how heavily we rely on them and the impact they have on our increasingly technological civilization; they have to evolve by overcoming the current challenges of our society, such as sustainability,” said Xavier Marin. With more than 20 years of experience in managing large technological projects, the CEO knows that “technically and economically viable renewable-based alternatives are needed, compared to traditional polymers that are mainly obtained from petroleum”.

In this context, PLA (polylactic acid) is the only renewable-based bioplastic that has managed to establish itself in the market; the rest still face difficulties in scaling up both technically and economically. Only Dan*na’s PLH, like PLA, is obtained from lactic acid and uses similar industrial processes, but it outperforms it in mechanical properties by being an electrical insulator.

Biodegradation is a decisive factor in mitigating environmental impact. Unlike conventional plastics, a biodegradable material decomposes naturally, preventing the accumulation of microplastics and toxic substances in oceans, soils and organisms. “PLH comes from renewable sources, such as lactic acid or organic waste, which facilitates its complete degradation without leaving residues, while maintaining advanced technical properties, ideal for industrial and medical applications,” said Marin.

Great potential in key sectors: microelectronics and biomedicine

Resins are essential materials in modern industry because of their strength, durability and stability under extreme conditions. Thermosetting resins are particularly noteworthy, as they are polymers that, when hardened, form structures that are highly resistant to heat, pressure and chemicals. However, most of these resins come from fossil sources, have a high environmental impact and cannot be recycled once hardened, making them a challenge for a world urgently seeking sustainable solutions.

While until now most thermosetting resins have come from fossil fuel sources, PLH is a bio-based thermosetting resin, mouldable and able to harden while maintaining its resistance to heat and demanding environments, even above 300 °C. Thanks to its durability, structural stability, and sustainability, it is presented as an ecological alternative to conventional plastics.

In terms of electronics, these qualities make it a particularly attractive material for the flexible electronics sector, a growing field that demands high-performance, resistant and sustainable materials, with the potential to be used in displays, sensors, RFID tags, smart fabrics and advanced packaging for cosmetics, pharmaceuticals or even food.

In the field of biomedicine, PLH has been tested in human cells, proving to be completely safe and compatible with the organism. Dan*na’s studies, developed in collaboration with Hospital Vall d’Hebron, confirm that this biomaterial can promote cell regeneration even faster than stem cells, according to the trials, making it a promising option for implants and single-use medical devices for organ and tissue regeneration.

Currently, with several competitive projects under way and more than three million euros raised in public and private funding, Dan*na is completing a key stage. After three years in the accelerator BCN Health Booster, promoted by the PCB and Barcelona City Council, with the support of Barcelona Activa and the collaboration of Biocat, the start-up has seen its technology internationally recognised with the granting of a worldwide patent and a new round of investment.