Biobased polymers and materials are desperately needed to replace fossil-based materials in the world’s transition to a more sustainable lifestyle. In this article, Avantium describes the path from invention towards commercialization of their YXY^® plants-to-plastics Technology, which catalytically converts plant-based sugars into FDCA—the chemical building block for PEF (polyethylene furanoate). PEF is a plant-based, highly recyclable plastic, with superior performance properties compared to today’s widely used petroleum-based packaging materials. The myriad of topics that must be addressed in the process of bringing a new monomer and polymer to market are discussed, including process development and application development, regulatory requirements, IP protection, commercial partnerships, by-product valorisation, life cycle assessment (LCA), recyclability and circular economy fit, and end-of-life. Advice is provided for others considering embarking on a similar journey, as well as an outlook on the next, exciting steps towards large-scale production of FDCA and PEF at Avantium’s Flagship Plant and beyond.

To quickly and drastically reduce CO₂emissions and meet our ambitions of a circular future, we need to develop carbon capture and storage (CCS) and carbon capture and utilization (CCU) to deal with the CO₂that we produce. While we have many alternatives to replace fossil feedstocks for energy generation, for materials such as plastics we need carbon. The ultimate circular carbon feedstock would be CO₂. A promising route is the electrochemical reduction of CO₂to formic acid derivatives that can subsequently be converted into oxalic acid. Oxalic acid is a potential new platform chemical for material production as useful monomers such as glycolic acid can be derived from it. This work is part of the European Horizon 2020 project “Ocean” in which all these steps are developed. This Review aims to highlight new developments in oxalic acid production processes with a focus on CO₂‐based routes. All available processes are critically assessed and compared on criteria including overall process efficiency and triple bottom line sustainability.

High Throughput experimentation has been well established as a tool in early stage catalyst development and catalyst and process scale-up today. One of the more challenging areas of catalytic research is polymer catalysis. The main difference with most non-polymer catalytic conversions is the fact that the product is not a well defined molecule and the catalytic performance cannot be easily expressed only in terms of catalyst activity and selectivity. In polymerization reactions, polymer chains are formed that can have various lengths (resulting in a molecular weight distribution rather than a defined molecular weight), that can have different compositions (when random or block co-polymers are produced), that can have cross-linking (often significantly affecting physical properties), that can have different endgroups (often affecting subsequent processing steps) and several other variations. In addition, for polyolefins, mass and heat transfer, oxygen and moisture sensitivity, stereoregularity and many other intrinsic features make relevant high throughput screening in this field an incredible challenge. For polycondensation reactions performed in the melt often the viscosity becomes already high at modest molecular weights, which greatly influences mass transfer of the condensation product (often water or methanol). When reactions become mass transfer limited, catalyst performance comparison is often no longer relevant. This however does not mean that relevant experiments for these application areas cannot be performed on small scale. Relevant catalyst screening experiments for polycondensation reactions can be performed in very efficient small scale parallel equipment. Both transesterification and polycondensation as well as post condensation through solid-stating in parallel equipment have been developed. Next to polymer synthesis, polymer characterization also needs to be accelerated without making concessions to quality in order to draw relevant conclusions.

To meet EU CO₂ emission targets, we need to replace most fossil-derived plastics with renewable alternatives. To stop endless pollution by accumulating non degradable plastics we need future plastics to be closed-loop recyclable and/or biodegradable.

The combination of the predicted polymer market growth and the emergence of renewable feedstocks creates a fantastic opportunity for sustainable polymers. To replace fossil-based feedstock, there are only three alternative sustainable carbon sources: biomass, CO₂, and existing plastics (via mechanical and/or chemical recycling). The ultimate circular feedstock would be CO₂: it can be electrochemically reduced to formic acid derivatives that subsequently can be converted into useful monomers such as glycolic acid. This work is part of the European Horizon 2020 project “Ocean” in which the steps from CO₂ to glycolic acid are developed. Polyglycolic acid (PGA) and poly(lactide-co-glycolide) (PLGA) copolyesters with high lactic acid (LA) content are well-known. PGA is very difficult to handle due to its high crystallinity. On the other hand, PLGAs with high LA content lack good oxygen and moisture barriers. The aim of this work is to understand the structure–property relationships for the mostly unexplored glycolic acid rich PLGA copolymer series and to assess their suitability as barrier materials. Thus, PLGA copolymers with between 50 and 91 mol % glycolic acid were synthesized and their properties were evaluated. Increased thermal stability was observed with increasing glycolic acid content. Only those containing 87 and 91 mol % glycolic acid were semicrystalline. A crystallization study under non-isothermal conditions revealed that copolymerization reduces the crystallization rate for PLGA compared to polylactic acid (PLA) and PGA. While PGA homopolymer crystallizes completely when cooled at 10 °C·min^–1, the copolymers with 9 and 13% lactic acid show almost 10 times slower crystallization, which is a huge advantage vis-à-vis PGA for processing. The kinetics of this process, modeled with the Jeziorny-modified Avrami method, confirmed those observations. Barrier property assessment revealed great potential for these copolymers for application in barrier films. Increasing glycolic acid content in PLGA copolymers enhances the barrier to both oxygen and water vapor. At room temperature and a relative humidity below 70% the PLGA copolymers with high glycolic acid content outperform the barrier properties of polyethylene terephthalate.