EXILVA · Project

First Large-Scale Plant Turning Wood Pulp Into High-Performance Bio-Based Material

manufacturingMarket-readyTRL 9

h2020-exilva.com

Imagine taking ordinary wood from Norwegian spruce trees and breaking it down into ultra-fine cellulose fibers — so small they create a gel-like material with surprising properties. This material, called microfibrillated cellulose (MFC), can replace petroleum-based additives in paints, adhesives, composites, and personal care products. The EXILVA project scaled up production from a small pilot line making 50-70 tons per year to a full commercial plant producing 1000 tons per year — making this bio-based ingredient available in bulk for the first time ever.

By the numbers

1000 tons/year

Commercial plant production capacity

50-70 tons/year

Previous pilot plant capacity

Consortium partners

Countries in consortium

71%

Industry partner ratio in consortium

Total project deliverables

The business problem

What needed solving

Many manufacturers still depend on petroleum-based additives — thickeners, binders, rheology modifiers — that are expensive, environmentally problematic, and increasingly targeted by regulation. Bio-based alternatives have existed in labs, but nobody could produce them at the volumes industry actually needs. Until now, microfibrillated cellulose was a promising material stuck at pilot-scale quantities of 50-70 tons per year, far too little for serious industrial adoption.

The solution

What was built

A full-scale commercial production plant producing 1000 tons per year of microfibrillated cellulose from Norwegian spruce wood. The project also produced wood panel prototype samples at pilot scale demonstrating MFC in real product applications, and established quality control, process parameters, and logistics for stable full-scale production.

Audience

Who needs this

Paint and coatings manufacturers replacing synthetic thickenersWood panel and composite producers seeking bio-based bindersAdhesive manufacturers looking for sustainable formulation ingredientsPersonal care companies replacing microplastics with natural alternativesPackaging companies wanting bio-based barrier and coating materials

Business applications

Who can put this to work

Paints & Coatings

mid-size

Target: Paint and coatings manufacturers looking to replace synthetic additives

If you are a coatings manufacturer dealing with rising costs for petroleum-based thickeners and rheology modifiers — this project built a 1000 tons/year production plant for microfibrillated cellulose that works as a bio-based alternative. MFC improves sag resistance, stability, and film properties while letting you market a greener product. The wood panel prototype samples confirm it works at industrial scale in coating-dependent applications.

Adhesives & Construction Materials

any

Target: Adhesive producers and wood panel manufacturers

If you are a wood panel or adhesive manufacturer struggling with formaldehyde regulations and looking for stronger bio-based binders — this project demonstrated MFC in wood panel production at pilot scale. The consortium includes 5 industry partners across 6 countries who validated the material in real product formulations. MFC can reduce synthetic binder content while maintaining or improving mechanical performance.

Personal Care & Cosmetics

SME

Target: Cosmetics formulators seeking natural-origin ingredients

If you are a personal care company under pressure to replace microplastics and synthetic thickeners with natural alternatives — MFC from this project is a plant-based rheology modifier produced at commercial scale of 1000 tons per year. It is derived entirely from Norwegian spruce, giving you a clear sustainability story. The material is now commercially available, meaning you can source it without supply chain uncertainty.

Frequently asked

Quick answers

What does MFC cost compared to synthetic alternatives?

The project specifically aimed to demonstrate that the flagship plant investment would be profitable, meaning cost competitiveness was a core goal. Pricing details are not published in the project data, but scaling from 50-70 tons/year to 1000 tons/year was designed to bring unit costs down to commercially viable levels. Contact the coordinator for current pricing.

Can this be supplied at industrial volumes?

Yes — the entire point of this flagship project was to scale production from a pilot plant at 50-70 tons per year to a full commercial plant at 1000 tons per year. This makes MFC available in bulk industrial quantities for the first time. Borregaard now operates this plant commercially under the Exilva brand.

What is the IP and licensing situation?

Borregaard AS, a major Norwegian biorefinery company, is the coordinator and plant operator. They sell MFC commercially under the Exilva brand name. Based on available project data, licensing would need to be discussed directly with Borregaard, though they appear to operate a direct supply model rather than licensing the technology.

What industries has this been tested in?

The EuroSciVoc classifications indicate testing in coatings and films, composites, and applications tied to the sustainable economy. A specific deliverable confirms wood panel prototype samples produced with MFC at pilot scale. The project targeted a wide range of market segments beyond these.

Is this still just research or can I buy it today?

This went well beyond research. The project was a flagship industrial demonstration (BBI-IA-FLAG funding type) that built and operated a 1000 tons/year commercial plant. The project closed in 2020 and Borregaard continues to sell MFC commercially. This is a market-ready product.

What regulations apply to MFC in my products?

The project identified standards and regulation as one of its grand challenges for market penetration. Based on available project data, specific regulatory outcomes are not detailed, but the consortium worked on establishing quality control and product standards during the project. Check with Borregaard for current regulatory status in your application area.

Consortium

Who built it

The EXILVA consortium is heavily industry-driven with 5 out of 7 partners coming from the private sector (71% industry ratio), which is a strong signal that this technology was built for commercial reality, not academic publication. Led by Borregaard AS — a well-established Norwegian biorefinery company — the consortium spans 6 countries (DE, EL, FR, NO, SE, UK) covering major European markets. Three SMEs participated, ensuring the technology was validated not just by large corporates but also by smaller companies that would need practical, cost-effective solutions. The single university and single research partner provided technical support without the project becoming research-heavy. This is exactly the kind of consortium you want to see when evaluating whether a technology is ready for your supply chain.

BORREGAARD ASCoordinator · NO
CHIMAR (HELLAS) AE - ANONYMI VIOMICHANIKI KAI EMPORIKI ETAIREIA CHIMIKON PROIONTONparticipant · EL
AYMINGparticipant · FR
KUNGLIGA TEKNISKA HOEGSKOLANparticipant · SE
NORSUS NORSK INSTITUTT FOR BAEREKRAFTSFORSKNING ASparticipant · NO
UNILEVER U.K. CENTRAL RESOURCES LIMITEDparticipant · UK

How to reach the team

Borregaard AS (Norway) — a major biorefinery company. Look for their Exilva product division or business development team.

Order a report on this consortium See BORREGAARD AS profile →

Next steps

Talk to the team behind this work.

Want an introduction to the Exilva team at Borregaard? SciTransfer can arrange a direct meeting to discuss supply options, pricing, and technical specifications for your application.

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