Location: Renewable Product Technology Research
2025 Annual Report
Objectives
The goal of this project is to create new chemical, biochemical, and chemocatalytic processes for economically producing value-added products from biomass, particularly from plant lipids and lignocellulose. Project team members will collaborate within the project, with other ARS researchers, and external partners to reach the following objectives:
Objective 1. Enable biochemical/chemical processes to convert commodity crops, crop oils, and byproducts into value-added commercial bioproducts.
Objective 2. Develop innovative lipid and biopolymer-based encapsulation systems for delivering, preserving, or promoting the activity of bioactive ingredients.
Objective 3. Resolve difficult catalytic processes to produce consumer products and industrial chemicals from crop residue, lignocellulosics, and biorefinery byproducts.
Approach
This research will enhance the economic viability and competitiveness of U.S. agriculture commodities by expanding domestic and global market opportunities associated with the growing bioeconomy through the development of environmentally friendly, value-added food and non-food biobased technologies and products. Plant lipids such as vegetable oil and lecithin are already available in high purity, while lignocellulose is abundant yet chemically complex. To properly exploit these valuable resources, new chemical, biochemical, and chemocatalytic processes must be developed that selectively generate higher value products. The challenge, therefore, centers on finding the most effective chemical, biochemical, and/or chemocatalytic conversion methods, optimizing process reaction conditions for effecting the desired biomass transformations, isolation and purification of the targeted bioproducts, and demonstrating that the bioproducts have equivalent or superior properties to commercially available products.
We have developed several distinctive and innovative approaches to reaching our goal. Our approach involves finding and modifying (in some cases) those catalysts and processes that perform the desired biomass transformation. Biochemical/biocatalytic and chemocatalytic methods will be developed to produce select chemicals from vegetable oils and lignocellulosics. Isolated enzymes will be used to convert lipids and lipid byproducts to consumer-targeted products. Designed multi-layered phospholipids and polysaccharide-based nanoparticles will be used to enhance and deliver bioactive ingredients in food and cosmetics. The sourcing of starting materials from agricultural feedstocks and byproducts in each of these endeavors to find solutions to the barriers that exist in the creation of a biobased economy.
Progress Report
This report summarizes progress for this project, which began May 27, 2020, and terminated May 26, 2025. Research will be continued under the new project 5010-30600-003-000D, “Targeted Approaches to Marketable Agricultural-Based Products.”
Under Objective 1, significant progress was made to synthesize and purify phytochemically modified plant oils to develop new higher value uses and applications that drive demand for US agricultural commodities. Phytochemicals are compounds found in plants that offer numerous potential health and other benefits. ARS researchers in Peoria, Illinois, previously developed technology to bind a phytochemical called ferulic acid to plant oils, such as soybean, coconut, and hemp. Ferulic acid helps many types of plants survive by providing strong ultraviolet absorbing and antioxidant properties. Modified plant oils linked to ferulic acid provide similar ultraviolet absorbing and antioxidant properties that make them very attractive for applications in personal care products, including skin lotions and hair treatments. This ARS patented technology is now used to commercially manufacture a novel USDA Certified Biobased Product from soybean oil called FSG that is used in hundreds of consumer products.
As part of this project, ARS researchers further improved the technology used to produce modified plant oils. During the transformation, not all the ferulic acid gets bound to the oil. Methods were thus developed to remove nearly all the unreacted ferulic acid from the final product and recycle the ferulic acid for subsequent use. This improved production process is estimated to save up to 25% in starting material cost in the commercial production of modified soybean oil.
Additionally, researchers further enhanced the process by demonstrating the potential cost-savings of using unrefined, virgin oils instead of refined versions. This research demonstrated that the conversion process was equally efficient with less expensive virgin hemp seed oil compared to refined hemp seed oil. Furthermore, using the less costly oil as starting material did not affect the UV absorbance and antioxidant ability of the final product. It is estimated that using virgin oil instead of refined seed oil will provide an 11% cost savings in the manufacturing process. The hemp oil-based compounds are currently being tested for applications with consumer care products.
Under Objective 2, significant progress was made in developing innovative lipid and carbohydrate-based encapsulation systems for delivering, preserving, or promoting the activity of bioactive ingredients that expand market utilization of agricultural commodities. Encapsulation is a process of surrounding important compounds with a protective coating to enhance stability, control release, and improve bioavailability. This work focused on using ARS technology to produce a natural, water-insoluble polysaccharide made enzymatically from cane and beet sugar for the encapsulation process. Researchers then converted the polysaccharide to nanoparticles, which are microscopic particles that exhibit unique properties due to their size. The new biobased nanoparticles were capable of encapsulating bioactive compounds and were stable for months, even in the presence of extreme conditions.
ARS researchers then determined that the nanoparticles could encapsulate oils modified with ferulic acid to improve efficacy with formulation and delivery for consumer care products. The encapsulated oils were found to still impart ultraviolet absorbing capabilities to the nanoparticles. Additionally, ARS researchers demonstrated the nanoparticles containing encapsulated oils modified with ferulic acid could be used to form thin films with ultraviolet absorbing capabilities. These films are being studied by the team as biobased coatings for applications for ultraviolet light protection (e.g., coatings to protect seed from U.V. damage). This biobased nanoparticle technology was also effective at encapsulating other compounds, such as antimicrobial agents that combat crop diseases, prevent food spoilage, and improve food safety. ARS researchers are utilizing this technology for antimicrobial applications requiring films with antimicrobial properties (e.g., mold inhibitors for food), controlled release of antimicrobial compounds over time, and protection of antimicrobial agents that degrade quickly.
In support of Objective 3, significant progress was made on the development of new methods for converting agriculturally derived materials into commercially useful chemicals. In one area of work, ARS researchers in Peoria, Illinois, combined common agricultural sugars with oil from the Cuphea plant to make a new family of biobased surfactants. Surfactants are important compounds used in numerous applications including cleaning and personal care items. The sugars used in this development were glucose and maltose sourced from corn and lactose collected from the waste streams in cheese-making operations. The new surfactants made by ARS researchers make stable foams, function as emulsifiers, and have antimicrobial activity against common clinical and agricultural pathogens. Research showed that these surfactants were effective at killing the bacterial pathogen Erwinia, which causes fire blight in apples, pears, and other members of the rose family. Fire blight causes severe damage to crops resulting in estimated annual losses of $100 million in the U.S. alone.
Similar chemical processes were used by the team to make effective plasticizers for PVC plastic, which is commonly used in products such as wiring insulation, plastic films for food storage, credit cards, automotive interiors, and water pipes. Plasticizers are additives that make polymers soft and pliable. However, this common additive can have negative effects associated with leaching from the polymer into the environment. For this work, Cuphea seed oil was reacted with chemically modified sugars to form completely biobased plasticizers. These new plasticizers performed as well and sometimes even better than traditional plasticizers, which have an approximate global market size of over $3 billion, for making PVC films.
ARS researchers also performed research in support of Objective 3 by developing a novel method that uses electrical energy to convert ethanol to a chemical that can be used as a jet fuel additive and a precursor to biobased rigid and foam board insulation. This new electrochemical method allows production of chemicals that are not easily achieved by other techniques. This technology also further expands the use of ethanol, which directly benefits corn, sugarcane, beet sugar, and sorghum producers.
In addition, new technology was developed to convert butanol, another type of alcohol that can be made from corn sugars, into a variety of chemicals that are used in manufacturing plastics, fuels, and food ingredients. The process created by the team converted butanol into the industrially important chemical called 2-ethylhexanol, which has a $6 billion global market and is widely used in the manufacturing of plastics and as an ingredient in personal care products. This new production method had higher productivity and easier product recovery compared with traditional processes. This biobased chemical provides farmers and manufacturers with a biobased drop-in replacement for existing markets to help meet the anticipated growing demand for this product.
Researchers further modified this technology to convert butanol into precursors for aviation fuels. Global demand for sustainable aviation fuel produced from biomass is growing and is expected to reach 5% of total jet fuel consumption by 2030. In direct response to this growing demand, the technology developed by ARS will expand international markets for American agricultural commodities and boost energy exports. Lastly, new processes were developed to convert butanol into the flavoring and fragrance compound butyl butyrate, which has a $240 million global market. Unlike traditional methods, this simplified technology converts butanol directly to butyl butyrate with the only byproduct being hydrogen gas that can be burned as fuel or sold for use in other manufacturing processes. Like the 2-ethylhexanol production method, this technology provides manufacturers with a drop-in biobased material to further economic development of agriculture products.
Finally, ARS researchers developed safer and more efficient methods to produce massoia lactone from corn, sugarcane, and/or beet sugar crops. Massoia lactone is traditionally produced from the bark of massoia trees native to southeast Asia and is primarily used in fragrances and flavorings. It currently has a global market revenue of $370 million. This new process provides a domestic route to produce this valuable chemical from agricultural commodities. The process is easily scalable, and the only byproduct of the new technology is water. The developed technology will enable the production of a high-value product at biorefineries leading to new economic opportunities in rural America.
This research has been extremely successful with developing innovative biobased products and technologies that create new market markets, enhance agricultural byproduct utilization, and increase economic resilience by diversifying market opportunities for farmers and producers.
Accomplishments
1. Domestic production of essential oil from agricultural commodities. Massoia lactone is an essential oil commonly used in fragrances and flavorings for its coconut-like aroma. It is currently produced in Southeast Asia from the bark of Massoia trees and has a market size of $370 million. ARS researchers in Peoria, Illinois, developed a new method to produce massoia lactone from commodity crops, such as corn, sugarcane, and/or beet sugar crops. This new technology uses materials that are safe to handle, do not produce waste, and are easily scalable. This work benefits farmers and producers by creating new market opportunities for their agricultural commodities and providing new safe and economically sustainable domestic supplies for this valuable chemical.
2. Production of UV absorbing hemp oil for consumer care products. Consumer demand for natural UV blockers is rising due to growing awareness of potential health and environmental risks associated with synthetic sunscreens. ARS researchers in Peoria, Illinois, previously developed technology to create a USDA Certified Biobased UV absorbing product from soybean oil, which is currently used in hundreds of consumer care products. To further expand the use of this technology with other agricultural commodities, ARS researchers developed a similar modified UV absorbing oil from hemp. Cosmetics and personal care products are a major component of the global hemp oil market predicted to reach almost $2 billion in the coming decade. ARS researchers also demonstrated that the modified hemp oil production process was equally efficient with less expensive virgin hemp seed oil compared to refined hemp seed oil. In addition, using the less costly oil as starting material did not affect the UV absorbance and antioxidant properties of the final product. It is estimated that using virgin oil instead of refined seed oil will provide an 11% cost savings in the manufacturing process. This research creates new, expanded market opportunities for farmers and provides consumers with natural biobased alternatives for consumer care products.
Review Publications
Wegener, E.C. 2025. Vapor phase coupling of n-butanol over the mixed catalyst system PdZn/SiO2+TiO2. Reaction Chemistry & Engineering. https://doi.org/10.1039/D4RE00474D.
Manamperi, H.D., Jackson, M.A., Wegener, E.C., Vermillion, K.E. 2025. Selective oxidation of ethanol on a nickel foam electrode followed by aldol condensation with furfural: an electrochemical approach for the utilization of biomass-derived molecules. ACS Electrochemistry. https://doi.org/10.1021/acselectrochem.4c00094.
Evans, K.O., Compton, D.L., Appell, M.D. 2025. Spectroscopic and theoretical evaluation of feruloyl derivatives: Insights into their electronic properties. Results in Chemistry. https://doi.org/10.1016/j.rechem.2025.102225.
Liu, Z., Cheng, H.N., Biswas, A., Jackson, M., Qureshi, N. 2024. Nanocomposites prepared in supercritical carbon dioxide from epoxidized soybean oil, citric acid, and cellulose nanofibers. Journal of Polymers and the Environment. https://doi.org/10.1007/s10924-024-03471-7.
Colombatti Olivieri, M.A., Price, N.P., Jackson, M.A., Bannantine, J.P. 2025. Evaluation of the cytotoxicity and antibacterial activity of a synthetic tunicamycin derivative against Mycobacterium avium complex. Frontiers in Microbiology. https://doi.org/10.3389/fmicb.2025.1604400.
Compton, D.L., Pero, B.A., Radloff, G.H., Evangelista, R.L., Winkler-Moser, J.K., Kenar, J.A., Cermak, S.C., Appell, M., Evans, K.O., Wegener, E.C., Rheay, H.T., Skory, C.D. 2025. Lipase-catalyzed transesterification of virgin and refined hemp seed oil with ferulic acid ethyl ester. Journal of the American Oil Chemists' Society. https://doi.org/10.1002/aocs.12849.
Jackson, M.A., Selling, G.W., Evans, K.O., Wegener, E.C. 2024. Cuphea as a source of fully crop-based plasticizers for Poly(vinyl chloride). ACS Sustainable Chemistry & Engineering. https://doi.org/10.1021/acssuschemeng.4c01592.
Rheay, H.T., Compton, D.L., Brownstein, K.J., Skory, C.D. 2025. Necessary reporting of reaction yield for method evaluation: Considering Knoevenagel synthesis of ferulic acid. Results in Chemistry. https://doi.org/10.1016/j.rechem.2025.102349.