EveryCarbon wins FLAIR subcontract to scale fossil-independent materials production

EveryCarbon, a high-performance shielding materials company developing engineered polyester systems for demanding industrial and construction environments, today announced it has been awarded a subcontract under the FLAIR project, led by Technische Universität Hamburg (TU Hamburg), to scale its circular diol production process from laboratory development to a 10,000-litre (10 m³) industrial pilot at Popp Feinkost.

EveryCarbon has engineered high-performance polyester ECOne, developed initially for performance insulation in demanding building environments and industrial manufacturing applications. 
This project supports the industrial-scale validation of the circular diols that feed into ECOne™ production, using existing infrastructure rather than new-build capacity.  

Scaling from laboratory to industrial pilot is one of the most demanding steps in bringing a new materials platform to market.  

The project is designed to demonstrate that EveryCarbon's production process can integrate directly into existing industrial infrastructure — reducing both the capital cost and the time required to reach industrial scale, while supporting the kind of supply resilience that increasingly matters to industrial and construction buyers exposed to volatile, fossil-derived supply chains.  

The subcontract sits within FLAIR — Funktionsmaterialien aus Lebensmittelabfällen durch prozess-Integriertes Recycling (Functional Materials from Food Waste through Process-Integrated Recycling) — a multi-year initiative converting food-processing side-streams into high-value functional materials through process-integrated recycling.

The project will follow a staged scale-up pathway. 

First, EveryCarbon will support retrofitting an existing 10 m³ tank to enable waste hydrolysis at Popp Feinkost's facility, integrating the fermenter with the site’s existing gas infrastructure and hot water supply systems, and preparing the system for continuous operation.  

Once the industrial fermentation system is operational, EveryCarbon will transport the food waste hydrolysate produced at Popp Feinkost to its pilot facility in Stuttgart. EveryCarbon will then further convert the waste hydrolysate to ECOne engineering resins. 

Partners at Hamburg University of Technology and the University of Hamburg will develop new monomers and polymers derived from the platform. Central to the project is its data layer, developed by Fraunhofer IPA, that will enable the early prediction of new material applications and significantly shorten development cycles.  

According to Sebastian Beblawy, Chief Executive Officer and Co-Founder of EveryCarbon, deploying a 10,000-litre fermentation process is a major step toward proving that existing industrial infrastructure is a key to unlocking the next fossil-independent manufacturing layer. 

“This project allows us to validate continuous production of the building block used in ECOne, while showing how existing industrial infrastructure can be repurposed to reduce dependence on fossil-derived materials.”  

Prof. Johannes Gescher, Head of the Institute of Technical Microbiology, TU Hamburg, said: 

“Food waste hydrolysate is a resource we've long known how to valorise scientifically, but rarely at a scale that matters industrially. The FLAIR project lets us take fermentation science out of the laboratory and validate it directly on an existing production site. 

Working with EveryCarbon on monomer and polymer development from this platform is a natural extension of research we've pursued for years, and this partnership gives us a real pathway to translate that work into materials with genuine industrial relevance.”