SUPREME-PILOTS develops advanced PLA-based copolymers — safer, more sustainable and circular alternatives to fossil-based plastics for high-value industrial applications.
The SUPREME-PILOTS project aims to develop a new generation of advanced bio-based plastics from renewable European raw materials. The project focuses on improving PLA, or polylactic acid, a plant-based plastic that can be produced from resources such as corn, sugar beet or other agricultural feedstocks.
PLA is already an important alternative to fossil-based plastics, but its current performance is still limited in some applications. Standard PLA can be too rigid or brittle, and it does not always provide enough heat resistance, flexibility or long-term durability for demanding industrial uses.
SUPREME-PILOTS addresses these limitations by developing improved PLA-based copolymers. Copolymers are plastics made from more than one type of chemical building block, which makes it possible to fine-tune their properties. In this project, PLA is combined with advanced bio-based components such as polyester-polyols and bio-based PTMG. These ingredients help adjust the final material’s flexibility, toughness, resistance and processability. Bio-based PTMG (Bio-PTMG) is a plant-derived version of PTMG (polytetramethylene ether glycol), a premium polyether polyol. It acts as a primary raw material to manufacture high-performance polyurethane, spandex, synthetic leather, and polyester resins.
A key technology used in the project is reactive extrusion. Extrusion is a continuous production process in which materials are heated, mixed and pushed through a machine. In reactive extrusion, the ingredients also undergo controlled chemical reactions during this process. This makes it possible to improve the material while producing it, without the need for solvents and with the potential to reduce waste, energy use and production costs.
Artificial intelligence and machine learning also support the development process. These tools analyse data from previous experiments and help predict which material combinations and processing conditions are most promising. As a result, researchers can reduce unnecessary testing and move more efficiently from laboratory development towards industrial-scale production.
The new materials will be tested on several industrial processing platforms, including large-scale 3D printing, rotational moulding, calendering, film production and lamination. These technologies cover a wide range of manufacturing routes, from producing large printed objects and hollow plastic parts to creating thin sheets, films and layered materials.
The project will demonstrate the performance of the new materials through real product prototypes in four main pilot applications.
In large-scale 3D printing, the materials will be used to create lightweight foamed sports and protective products, such as safety mats, playground floor tiles, wall protection systems and training blocks. These products are expected to combine low weight with impact absorption and durability.
In rotational moulding, the project will develop urban furniture components, especially outdoor planters or similar public-space products, as bio-based and recyclable alternatives to conventional polyethylene products.
In calendering, the new materials will be used to produce more sustainable resilient flooring for public, commercial, healthcare and sports environments, with the aim of reducing or replacing conventional rubber and fossil-based elastomers.
In film production and lamination, the project will develop flexible industrial signage and warning tapes as a bio-based alternative to PVC-based products, with good durability, printability, adhesion and recyclability.
These pilots ensure that SUPREME-PILOTS is not limited to material development, but also demonstrates how the new plastics can work in practical applications. The expected results include validated product prototypes, improved processing knowledge, scalable material production routes and a digital tool to support faster optimisation of new PLA-based formulations.
Circularity is a central element of SUPREME-PILOTS. This means considering the full life cycle of the material, including how it can be reused, recycled or recovered at the end of its use. The project will assess recycling options and end-of-life solutions for the developed products, including mechanical and chemical recycling routes. This supports a more circular economy, where materials remain in use for as long as possible and waste is reduced.
SUPREME-PILOTS follows the European Safe and Sustainable by Design approach. This means that safety and sustainability are considered from the beginning of the material design process, rather than added only at the end. The aim is to develop materials that are not only high-performing, but also safer for people and better for the environment.
By combining European raw materials, research knowledge, industrial cooperation and advanced technologies, SUPREME-PILOTS can help strengthen Europe’s role in the bio-based materials sector. The project supports the transition from fossil-based plastics to safer, more sustainable and more circular alternatives, while opening new high-value market opportunities in sectors such as sports, construction, urban infrastructure, transport, medical technology, electronics and energy.
The SUPREME-PILOTS consortium brings together 14 partners from seven European countries, combining the expertise of large companies, SMEs, research and technology organisations, and an association. The partners cover the full value chain and contribute complementary knowledge in materials, processing, product development, testing, standardisation, sustainability assessment, and innovation management.
SUPREME-PILOTS will apply the European Union’s Safe and Sustainable by Design framework to improve the sustainability, safety, and circularity of innovative materials and products. The project aims to achieve a reduction of more than 35% in CO₂-equivalent emissions, supporting the transition towards safer, more sustainable, and circular industrial value chains.
AITIIP is a Spanish Research and Technology Organisation and Technology Centre specialised in advanced manufacturing, plastic materials and their transformation processes — including extrusion, injection moulding, thermoforming, rotomoulding, calendering, film extrusion and large-format 3D printing. With over 25 years of experience, it bridges laboratory research and industrial application.
Within SUPREME-PILOTS, AITIIP acts as Project Coordinator. As leader of WP2 it coordinates industrial partners on technical constraints and processing parameters, and as leader of WP7 it drives exploitation, replicability and market strategy — including IP management, key exploitable results, standardisation roadmaps and business plans.
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