When imagining a sustainable future, one often thinks of a world without plastics. However, while that horizon is desirable, it is not realistic. "Plastics, for now, cannot disappear because they are omnipresent in contemporary society," assures Xavier Marín, CEO of Dan*na. In an increasingly technological world —with devices such as tablets, mobile phones, or computers manufactured from these components—, plastics remain essential. "We cannot do without plastics, but we can move towards a more sustainable model," insists Marín. In fact, of the more than 400 million tons of plastic produced annually, less than 2% come from biodegradable materials, as the vast majority are still derived from fossil materials such as petroleum.
Dan*na wants to contribute precisely to changing this model. The startup, located in the Barcelona Science Park (PCB), has developed the PLH copolyester, considered one of the most advanced bioplastics. Created from lactic acid —a compound naturally present in the human body and which can also be obtained from vegetable waste—, its manufacturing process allows to reduce CO₂ emissions by up to 75% compared to conventional plastics. Although it is completely biodegradable, the material presents a combination of resistance and versatility that makes it suitable for demanding sectors such as electronics, medicine, or cosmetics.
This bioplastic born in the PCB is increasingly closer to reaching the market, after the company has started the industrial production of this material in the Chempark chemical park, in Leverkusen (Germany). However, the company's origins date back to 2017, when Dan*na began its activity as a result of a personal concern of Marín. A computer scientist with a long career in public and private companies, after turning 40, he felt the need to create "something tangible."
"After a long professional career dedicated to a sector as intangible as IT, and even after having created two companies in this field, I wanted to create a physical object," confesses the CEO of Dan*na. An object that "would revolutionize sectors such as robotics or electronics, but in a sustainable way." With a curiosity cultivated since childhood, when he already dreamed of manufacturing robots and other futuristic objects, Marín focused on 3D printers, which at that time were beginning to become popular. However, his goal was not to manufacture these machines, but to focus on the printing material.
This is how he began to research sustainable plastics with the aim of creating a new viable alternative to petroleum derivatives. And he decided to do it from scratch: designing his own molecular structure. With a small research team and from the PCB, they explored different avenues until they developed a structure based on lactic acid and macrolactones, both compounds of natural origin. From these two elements, a new polymer is generated which, unlike other materials, does not require additives to be useful in different sectors.
The research has been possible thanks to the more than two million euros in public aid that the startup has attracted since its inception, through European projects or aid from institutions such as the Center for Industrial Technological Development (CDTI) or Acció. The company has also been boosted by BCN Health Booster, the accelerator for health companies created by the PCB together with Barcelona Activa and Biocat.
Another objective of the project was to find a molecular structure that would allow bioplastics to be manufactured without the use of bacteria, a common formula. "Although bacteria are promising in this type of application, they do not guarantee stability at an industrial scale," explains Marín. "Chemistry —and in our case green and sustainable chemistry— allows us to control the process and ensure quality also in industrial phases," says the CEO of Dan*na. After almost six years of trial and error, in 2023 they obtained the worldwide patent for PLH.
With the patent under its arm, the company decided to open its first round of investment to scale the activity. The management company BeAble Capital led an operation of more than one million euros —with 800,000 contributed by the firm— which has allowed the startup to complete another decisive step this year: the start of industrial production. Now, the forecast is to manufacture more than 300 tons annually at the Chempark plant in Leverkusen.
From labels to exfoliants
Currently, Dan*na has already validated its material for the electronics sector together with the CSIC, and more than ten large corporations worldwide —from sectors ranging from dyes to resins or electronic devices— are already testing PLH in their own production lines. In the electronics sector, the material presents essential properties: resistance to high temperatures —being able to withstand more than 300 degrees, a differential characteristic compared to other existing bioplastics—; a great electrical insulation capacity; and remarkable flexibility, even superior to that of conventional plastics such as polypropylene.
This flexibility makes it ideal for the production of textile labels or electronic devices: "PLH absorbs impacts better than conventional polymers, with the ability to resist blows, a key aspect in the manufacture of drones, mobile phones or electronic boards," remarks Marín.
Although electronics is its main focus, the material is also being tested in other areas, such as medicine. Together with Hospital Vall d'Hebron, Dan*na has passed the first preclinical trials to use PLH as a material for implants and medical devices, demonstrating that it promotes bone and cartilage regeneration. As it is a material derived from lactic acid, the body can absorb it in about 18 months, which reduces the need for second interventions and opens the door to new solutions in regenerative medicine.