We are witnessing a notable and growing shift toward bio-based materials in the coatings industry. This movement is driven by multiple converging factors that reflect broader societal, regulatory and market trends. Manufacturers and end users alike are seeking ways to reduce volatile organic compounds (VOCs), decrease reliance on fossil fuels and lower greenhouse gas emissions. Regulatory landscapes are changing rapidly, with governments worldwide introducing stricter guidelines and incentives. For instance, the European Union has set a target to reduce CO2 emissions by 55% by 2030, prompting both industries and consumers to adopt products with a lower carbon footprint.

These drivers are not fleeting trends but foundational changes that will shape the industry’s future for years to come. As such, bio-based coatings have emerged as a key avenue for innovation. The promise of bio-based solutions lies in their ability to marry reduced carbon emissions with efficacy, providing manufacturers with opportunities to meet both CO2 emission reduction targets and customer expectations.

The Fundamentals of Bio-Based Coatings

Bio-based coatings typically replace petroleum-derived raw materials with renewable feedstocks sourced from plants or other biological materials. Unlike traditional fossil fuel-based binders and resins, bio-based alternatives are formulated from renewable carbon sources such as vegetable oils, starches or biopolymers like polyhydroxyalkanoates (PHAs). Leveraging these materials in bio-based coatings contributes to a reduction in carbon emissions and resource consumption over the product life cycle, primarily through the use of renewable feedstocks and energy-efficient production processes.

However, the shift from fossil-based to bio-based binders is not a simple one-to-one substitution. Differences in chemical structure and physical properties necessitate adjustments in coating formulations. Key parameters such as viscosity, adhesion and drying time can vary significantly, requiring careful reformulation to maintain or improve performance characteristics. For example, bio-based binders may exhibit different film formation behavior or interact differently with pigments and additives, influencing the final coating’s durability and appearance.

Manufacturers must therefore strike a balance between bio-based content and technical performance. Achieving this equilibrium is crucial to the successful and widespread adoption of bio-based coatings, as end users demand products that do not compromise on quality, longevity or application efficiency. This technical challenge highlights the importance of formulation expertise and iterative development processes in optimizing bio-based coating systems.

Navigating Challenges in Adoption

Despite growing interest and momentum, several challenges remain in scaling bio-based coatings for widespread commercial use. Performance trade-offs compared to conventional binders remain a central concern. While progress has been made, some bio-based alternatives still fall short in specific properties such as chemical resistance, adhesion under certain conditions or drying speed. These differences require manufacturers to invest in formulation adjustments and application testing to provide equivalency or improvement over traditional products.

Cost is another significant hurdle. Raw materials often carry a premium due to factors such as feedstock availability, processing complexity and scale of production. This higher input cost can translate into more expensive finished coatings, which may pose adoption barriers in price-sensitive markets. However, innovation offers pathways to mitigate these costs. For instance, advanced application techniques such as multilayer curtain coating can reduce the volume of coating required by up to 15% while maintaining performance, potentially offsetting the premium costs of raw materials.

Supply chain consistency and transparency also play vital roles. Sourcing for bio-based solutions must avoid competition with food production and adhere to environmental impact standards. Manufacturers and suppliers must establish transparent traceability of bio-feedstocks, certifying that materials are responsibly sourced and verified as nonfood competing. For example, certifications such as the USDA BioPreferred Program or ISCC PLUS can provide traceability of material sourcing. Such transparency builds trust with customers and regulators alike, who are increasingly scrutinizing the origins and life cycle impacts of products.

Regulatory complexity adds another layer of challenge. Unlike traditional coatings, bio-based products often lack standardized thresholds or consistent criteria for labeling and certification. This can create confusion in the marketplace and complicate marketing and compliance efforts. The absence of harmonized bio-based content definitions or certification protocols requires companies to navigate changing guidelines and often necessitates the establishment of their own internal standards for quality and bio-based content claims.

To overcome these challenges, technical collaboration and customer partnerships are invaluable. Access to specialized pilot coating facilities, such as Trinseo’s Midland Pilot Coating Facility in Michigan, and formulation expertise enables companies to co-develop solutions tailored to customer needs. Such collaborative approaches can accelerate qualification processes, enhance troubleshooting and foster confidence in bio-based alternatives, supporting broader adoption across industries.

Current and Emerging Applications

Bio-based coatings are gaining traction across a range of industries with diverse application demands, as evidenced by the global bio-based coatings market, which is projected to grow from $10.4 billion in 2022 to $18.8 billion by 2030, at a compound annual growth rate (CAGR) of 7.8%. The automotive sector, for example, is increasingly adopting bio-based binders in coatings and adhesives to meet stringent emissions regulations, like the U.S. Environmental Protection Agency’s (EPA) National VOC Emission Standards.

Construction materials also present significant opportunities, where bio-based coatings can reduce carbon emissions compared to their fossil-based equivalents for building envelopes, roofing and insulation products without sacrificing durability or weather resistance.

Packaging is another rapidly growing market for bio-based coatings, driven by heightened consumer and regulatory pressure to reduce waste, evidenced by the European Union’s Single-Use Plastics Directive, which took effect in 2021. Emerging applications in aerospace, marine, industrial equipment and healthcare are also exploring bio-based coatings as part of broader sustainability goals. Across these varied fields, bio-based materials help brands enhance their credentials and satisfy increasingly sophisticated customer expectations.

The Role of Sustainability Metrics

As bio-based coatings mature, robust metrics become essential for substantiating environmental claims. Life cycle assessments (LCA) and product carbon footprint (PCF) analyses provide quantitative evaluations of environmental impacts across the product life cycle — from raw material extraction through manufacturing, use and end-of-life disposal. These tools enable manufacturers and customers to make informed decisions based on transparent data rather than relying on assumptions or marketing assertions.

For example, an LCA conducted on a bio-based coating system intended for automotive applications demonstrated a 25% reduction in overall carbon emissions compared to traditional alternatives. This reduction was achieved through the use of renewable feedstocks and energy-efficient production processes, aligning with the automotive industry’s goals to incorporate more sustainably advantaged solutions.

Ongoing LCA initiatives help identify areas for improvement within bio-based formulations, support regulatory compliance and facilitate credible communication of sustainability advantages to stakeholders. For example, Trinseo’s efforts in LCA studies and PCF analyses are helping to refine products and make data-driven decisions. In fact, PCF data was completed for nearly 6,000 Trinseo solutions in 2024, enabling transparent comparisons between the company’s virgin and sustainably advantaged materials.

Moreover, transparency regarding these metrics is increasingly demanded by regulators, brand owners and consumers alike. As these considerations become integral to procurement and product development, quantifiable data will shape market competitiveness and innovation priorities. Companies that invest early in comprehensive LCA and PCF studies are positioned to lead by demonstrating verifiable contributions to environmental stewardship.

Navigating the Challenges of Bio-Based Coatings

While performance and cost challenges persist, the growing market demand, regulatory pressures and sustainability imperatives make the shift toward bio-based coatings both inevitable and necessary. Successfully navigating this transition requires a combination of technical expertise, innovation capabilities and a collaborative approach with customers and supply chain partners. Companies that proactively engage with the technical complexities of bio-based formulations and invest in overcoming market barriers will be best positioned to lead the coatings industry onward.

Learn more about the latest developments in sustainable coatings.