Think about your favourite waterproof jacket or that sleek glass bottle for your face cream. We love them for their performance and look, but rarely consider the invisible chemicals behind them. For decades, many high-performance coatings have relied on PFAS, or “forever chemicals,” which do not break down in our environment.
What if we could have the performance we love without the environmental cost?
This is the challenge the BIO-SUSHY project took on. We’re pioneering a new generation of protective coatings that are just as effective, but safer and smarter. The hero of this story? Hybrid sol-gel coatings.
Figure 1: Our hybrid sol-gel coatings are water and oil-repellent.
So, What Exactly Is This “Sol-Gel”?
Let’s skip the complex jargon. Imagine making an ultra-thin protective varnish from scratch. You start with a liquid solution (the “sol”) that, through an ingenious process, transforms into a gel-like network able to cling to almost any surface.
The hybrid aspect makes this special. It combines the strength of glass-like materials with the flexibility of advanced plastics. This association occurs on a small scale, creating a thin yet strong shield. These hybrid materials are rigorously tested for safety and are non-toxic, ensuring they are safe for both your health and the environment.
Figure 2: Sol-gel process to create solid coatings from liquid solutions.
Why This Technology is a Game-Changer
The benefits of this approach are profound, especially compared to conventional, bulkier organic coatings. Because it bonds at a molecular level, you need only a fraction of the material to achieve better results.
- An Invisible, Powerful Shield: This coating is thinner than a human hair. Yet, this tiny layer provides strong mechanical, thermal, and chemical resistance, protecting against scratches, heat, and everyday wear and tear more effectively.
- Built-in Stain and Water Protection: It naturally keeps away water, oil, and stains. Best of all, we do this without using any harmful PFAS or “forever chemicals.”
- A Perfect, “Invisible” Feel: On glass packaging, the coating is nearly impossible to see. Because it is chemically similar to glass, it does not change how the packaging looks or feels. The packaging retains its aesthetic appeal and is smooth, just as designers intended.
- Clean and Hygienic: We can build in antimicrobial properties, helping keep your sportswear fresher and your cosmetic applicators cleaner.
Figure 3: Hybrid sol-gel coatings can repel stains from substances such as tomato sauce and milk.
Transforming Your Everyday Products
This isn’t just a lab experiment. This technology is making its way into products you use every day.
- For Your Wardrobe: Imagine outdoor jackets that are waterproof and breathable, or sportswear that fights odours over many washes. This technology makes that possible, more sustainably than before.
- For Your Cosmetics: That glass jar? It can now have a scratch-resistant, easy-to-clean coating that keeps it looking new, and reusable.
Our Green Promise: Performance You Can Feel Good About
At BIO-SUSHY, “sustainable” isn’t just a buzzword. It’s the foundation of everything we do.
- PFAS-Free, Full Stop: We’ve eliminated the need for harmful “forever chemicals,” avoiding chemicals linked to thyroid disease and cancer. This shift brings tangible benefits, promising safer products for personal use.
- Less is More: By using an ultra-thin coating, we reduce the amount of raw material needed, minimizing waste from the start.
- Cleaning Up Our Process: We are pioneering the use of water-based formulas for textiles and are rigorously reducing solvents in other areas, following Europe’s strict Safe and Sustainable by Design (SSbD) framework.
- Made to Last: When products last longer because they are better protected, you do not need to replace them as often. This reduces waste and is a clear win for the planet.
We are honest about the challenges, too. Earlier versions of this technology required high curing temperatures. A key part of our innovation has been to lower this energy need, making the process more efficient and eco-friendly. Despite these advances, challenges remain. Scaling the production process to industrial levels poses technical and cost obstacles, which we are working to overcome. We are also committed to further reducing production costs, ensuring these eco-friendly coatings remain accessible for a wide range of applications.
What’s Next? The Future is Smart and Sustainable.
The innovation doesn’t stop here. The BIO-SUSHY team is working on:
- Scaling up production for industry use
- Making the process more cost-effective
- Partnering with brands to test coatings in real-world conditions
And in the future, you might see:
- Self-Healing Surfaces: A tiny scratch that “heals” itself.
- Air-Purifying Fabrics: Jackets that can help break down air pollutants around you.
- Smart Sun Protection: Coatings that provide enhanced UV or infrared filtering.
The BIO-SUSHY project is leading this new wave of materials. We are showing that you can have both high performance and a healthy planet. By rethinking the thin layers that protect our products, we are helping to create a cleaner, more sustainable future, one jacket and one jar at a time.
