Bio-based epoxy resin from lignin for rigid plastic packaging extrusion
Lignin-derived epoxy resin synthesized via hydrogenolysis of pine wood offers a sustainable, BPA alternative for rigid plastic packaging. The bio-based prepolymer can replace 30-75% of petroleum-based epoxy, delivering improved flexibility and strength while maintaining thermal stability for extrusion manufacturing.
Overview
This research proposes a sustainable alternative to petroleum-derived resins used in rigid plastic packaging manufacturing. By synthesizing epoxy resin from lignin, the most abundant natural aromatic polymer on Earth, the approach addresses growing industry demand for bio-based materials that can replace bisphenol A (BPA)-based systems. The resulting resin is compatible with existing extrusion technologies and can be blended with conventional plastics such as HDPE, PET, and PP, enabling manufacturers to adopt renewable feedstocks without overhauling their production lines.
Technical specifications
Key features:
- Renewable feedstock: Native lignin extracted from pine wood, a widely available plant-derived biopolymer
- Depolymerization process: Mild hydrogenolysis breaks down native lignin into bio-oil intermediates
- Epoxy prepolymer synthesis: Bio-oil reacts with epichlorohydrin to produce epoxy prepolymers
- Blending flexibility: Prepolymers can substitute 30-75% of bisphenol A diglycidyl ether equivalent
- Curing compatibility: Works with standard curing agents including diethylenetriamine and isophorone diamine
- Performance improvements: Enhances flexibility by approximately 52% and strength by approximately 38% compared to conventional packaging materials
- Thermal stability: Higher thermal stability than petroleum-based resins, making it well-suited for extrusion processes
- Processing compatibility: Can be processed alongside existing resins (HDPE, PET, PP) used by current plastic manufacturers
Technology readiness level
This technology is at an early-to-mid stage of development. The synthesis pathway has been established and the structural modification of native lignin into bio-based epoxy resin has been demonstrated. Future validation will focus on scaling the hydrogenolysis depolymerization process, optimizing prepolymer blending ratios with conventional resins, and confirming performance enhancements in extrusion-based rigid packaging applications. Further work is needed to validate mass-production feasibility and long-term material performance in commercial manufacturing environments.
About Yonsei University
Yonsei University is a comprehensive private research university based in Seoul with an additional international campus in Songdo, combining a broad academic enterprise with a major clinical footprint. For industry, co-located academic and clinical facilities enable problem-driven collaboration from early discovery through validation, and shared core labs and prototyping spaces streamline testing. The Songdo campus sits within the Incheon Free Economic Zone’s biomanufacturing hub, giving partners proximity to large‑scale production and a dense supplier network. Research is supported by competitive national funding through the National Research Foundation of Korea and relevant ministries, and a dedicated technology transfer office manages IP, licensing, and startup formation.
Inquire about this partnering listing
Looking for
Industry applications
delivered to your inbox.