Development of safe and sustainable methods to produce polyurethane and epoxy thermosets from bio-based sorbitol and isosorbide based precursors.

Conventional thermoset resins such as polyurethanes (PUs) and epoxies rely on fossil-based polyols, aromatic isocyanates (TDI, MDI), bisphenol A (BPA) and epichlorohydrin (ECH), all of which are associated with volatile organic compound (VOC) emissions, occupational hazards, and risks to human and environmental health. Growing concerns over their toxicity, persistence, and end-of-life limitations have fostered research on biobased alternatives. However, current solutions are constrained by limited feedstock availability and by recycling processes that remain energy- and solvent-intensive. BIOSUSSET addresses these challenges by developing novel biobased thermoset resins with high renewable content sourced from agrifood waste. Through pressurized hot water extraction and membrane filtration for polysaccharides, mechanochemistry for sugar conversion, and magnetic induction for sorbitol/isosorbide production, BIOSUSSET establishes sustainable, non-toxic building blocks for epoxy and PU synthesis. Hazardous substances will be eliminated or substituted: BPA and ECH will be replaced by epoxidized sorbitol and isosorbide derivatives, 5-hydroxymethylfurfural (5-HMF) and vanillin; sustainable PUs will be synthesized from sorbitol-based polyols and low-toxicity isocyanates; and non-isocyanate PUs (NIPUs) will be obtained from isosorbide carbonates. These innovations aim to lower VOC emissions, reduce aquatic toxicity, and minimize occupational exposure. The resulting materials will enable improved recyclability and circular value chains, validated in composites, adhesives, wind blades, and technical coatings. Comprehensive life cycle, toxicity, economic, and social assessments will ensure robust validation. BIOSUSSET delivers breakthrough innovation in polymer chemistry, supports net-zero and low-pollution manufacturing, and advances circularity in energy-intensive industries, fully aligned with the EU Green Deal and Chemicals Strategy.