Toray and PTT Global Chemical have developed a new process to produce fully bio-based Nylon 66 from cassava pulp waste, opening new opportunities for sustainable plastics and textile fibers.

Bio-based Nylon 66 from Cassava Waste: A New Step for Sustainable Plastics – Bio-based-nylon-66-cassava-waste

The transition toward low-carbon materials is accelerating across the global chemical and textile industries. One of the latest innovations comes from Japanese company Toray and Thailand-based PTT Global Chemical (GC), which have jointly developed a new production process for fully bio-based Nylon 66 starting from cassava pulp residues.

The technology represents an important step for the future of sustainable engineering plastics and textile fibers, especially as manufacturers search for alternatives to fossil-derived raw materials.

According to recent industry reports published this week, the two companies aim to commercialize the technology and begin textile sales based on this material by 2028.

From Agricultural Waste to High-Performance Polyamide

The new process uses cassava pulp, a byproduct generated during cassava root processing for food applications. Instead of becoming waste, the starch-rich residue is transformed into valuable chemical intermediates.

The production chain begins with a saccharification process developed by Toray, capable of converting starch residues into glucose. PTT Global Chemical then applies fermentation and refining technologies to obtain high-purity bio-muconic acid.

In the final phase, Toray converts the bio-muconic acid into bio-based adipic acid, one of the key building blocks of Nylon 66. The adipic acid is polymerized together with bio-based hexamethylenediamine (HMDA), resulting in a fully renewable polyamide 66.

The resulting material can be used for:

• Technical textile fibers
• Automotive engineering plastics
• Industrial components
• Consumer goods
• High-performance resin applications

Why Bio-based Adipic Acid Matters

Adipic acid is traditionally produced from petrochemical feedstocks, a process associated with significant greenhouse gas emissions, including nitrous oxide.

The Toray-GC approach replaces fossil resources with biomass-derived sugars and fermentation technologies, potentially lowering the environmental footprint of Nylon 66 production. Earlier research collaborations between the two companies already highlighted the environmental advantages of bio-based adipic acid pathways.

This development also aligns with the broader global shift toward bio-refineries and circular chemistry systems that valorize agricultural residues instead of relying exclusively on virgin fossil inputs.

The Role of Cassava in the Bioeconomy

Cassava is widely cultivated across Southeast Asia, especially in Thailand, which is one of the world’s leading exporters. The food processing industry generates large quantities of cassava pulp every year.

By transforming this residue into chemical feedstock, companies can create additional economic value while reducing industrial waste streams.

This approach fits within the growing bioeconomy model, where agricultural byproducts are reused in advanced manufacturing sectors such as:

• Bioplastics
• Sustainable textiles
• Packaging materials
• Bio-based chemicals
• Low-carbon polymers

Commercial Scale-Up Remains the Next Challenge

At the moment, the process has been validated at laboratory scale, including polymerization and fiber processing tests. The next phase will focus on industrial scale-up and cost reduction.

Toray and PTT Global Chemical are also working on building a dedicated supply chain capable of supporting future commercial volumes.

Industry analysts believe bio-based polyamides could become increasingly important as brands and manufacturers face stronger sustainability regulations and demand for low-carbon materials.

Recent developments in Asia’s circular materials sector show growing momentum around renewable and recycled feedstocks for the chemical industry.

A Strategic Move for Sustainable Textiles and Plastics

The partnership between Toray and PTT Global Chemical highlights how chemical innovation is evolving beyond traditional recycling toward fully renewable molecular platforms.

Unlike partially bio-based polymers, this new Nylon 66 aims to achieve a completely bio-based composition while maintaining the high mechanical performance required in demanding applications.

If industrial production becomes economically competitive, the technology could help reshape parts of the plastics and textile supply chain over the next decade.

 

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