This sbir phase i project will enable non-meltable, agriculturally derived- polymers to be converted into usable products for the food packaging and commodity products industries

The Department of Agriculture National Institute of Food and Agriculture awarded Green Materials LLC $175,000 under the Small Business Innovation Research (SBIR) Program on September 15, 2025.

Green Materials will design and develop a novel machine component and processing methodology to convert non-meltable, agriculturally-derived polymers into usable products for food packaging and commodity industries through injection-compression molding. The recipient will produce sample products using the new component and methodology, then collaborate with USDA scientists to test performance data and iteratively refine the design. The work addresses the technical hurdle of manufacturing compostable alternatives to petroleum-based plastics at scale by exploring advanced statistical process control methods to manage feedstock variability.

This Phase I project runs through May 14, 2027, and is performed in Merion Station, Pennsylvania. The SBIR Program supports small businesses in transforming scientific discovery into commercially viable and socially beneficial innovations, focusing on projects with high technical risk and significant commercial or societal potential.

Agriculturally-derived polymers are attractive starting materials because nature produces them. Consequently, chemical synthesis is not required. These agriculturally-derived polymers are also readily available in mass quantities. However, these agricultural feedstocks are non-meltable and cannot be transformed into a viscous melt as is required for traditional injection molding. Therefore, we must look beyond traditional manufacturing methods, and that is the aim of this phase i proposal. This phase i proposal's focus on optimized manufacturing will address the critical hurdle in making compostable alternatives to non-biodegradable plastics viable at scale. To manage the variability introduced by the agricultural feedstocks, we will explore advanced statistical process control methods, similar to those used in the food industry, to ensure consistent quality and performance in the final parts. The output will be a validated procedure on a novel machine component that works for non-meltable, agriculturally-derived polymers and can be used in injection-compression molding. We will design and develop the new machine component and processing methodology in-house, and then use them to produce sample products. These will be tested collaboratively with USDA scientists to gather performance data and iteratively refine the design of the new machine component and processing methodology. The development of cost-competitive, compostable alternatives to non-biodegradable plastics could revolutionize society, the economy, and the environment. By reducing dependence on petroleum and cutting down harmful chemical pollution, this technology can help tackle the growing plastic waste crisis. Economically viable compostable replacements offer a solution to the long-lasting damage caused by traditional plastics, decreasing waste in landfills and oceans. A key societal benefit is the reduction in plastic pollution, which lowers exposure to dangerous chemicals like carcinogens and endocrine disruptors, leading to better health and easing strain on healthcare systems. Economically, this technology promises to unlock new markets, create new jobs, and boost rural economies, all while supporting sustainable manufacturing and agriculture.