On May 13, 2025, Georgia Tech celebrated a major milestone in sustainable manufacturing with the ribbon cutting of its new Multiphase Forming Lab in the Paper Tricentennial Building. The event, hosted by the Renewable Bioproducts Institute (RBI), marked the official launch of a pioneering system that promises to revolutionize the papermaking industry.

The Multiphase Forming System, the only one of its kind in North America, dramatically reduces the amount of water needed in the paper production process. By using up to 70% less water, the system also significantly cuts down on the energy required for drying — traditionally one of the most energy-intensive steps in papermaking. This innovation, developed by principal investigator Cyrus Aidun, not only enhances efficiency but also supports broader sustainability goals by lowering greenhouse gas emissions.

The grand opening event featured remarks from Georgia Tech President Ángel Cabrera, Executive Vice President for Research Tim Lieuwen, and Carson Meredith, executive director of RBI, among others. Attendees included industry leaders, researchers, and students, all eager to witness the unveiling of a technology that has been five years in the making.

The Multiphase Forming project has garnered widespread interest from the paper and packaging industries. A recent extension of the research, funded by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (DOE-EERE), integrates this forming system with cutting-edge refining and drying technologies. Led by Meredith, this initiative aims to further reduce energy consumption and environmental impact in paper manufacturing. John Xu has been appointed to run the facility.

Meredith said, “Today is milestone in RBI’s history, as we continue to partner and innovate with the paper and pulp industry.  We’d like to share our gratitude with our researchers, students and industry sponsors International Paper, Kimberly Clark and Solenis.”

Every time you use your phone, open your computer or listen to your favorite music on AirPods, you are relying on critical minerals.

These materials are the tiny building blocks powering modern life. From lithium, cobalt, nickel and graphite in batteries to gallium in telecommunication systems that enable constant connectivity, critical minerals act as the essential vitamins of modern technology: small in volume but vital to function.

Yet the U.S. depends heavily on imports for most critical materials. In 2024 the U.S. imported 80% of rare earth elements it used, 100% of gallium and natural graphite, and 48% to 76% of lithium, nickel and cobalt, to name a few.

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In mid-April Georgia Tech's Renewable Bioproducts Institute hosted a mini-symposium discussing the challenges and potential solutions to integration at different scales and levels of abstraction.
 
Challenges Discussed:
-Technical Compatibility: Ensuring biomass-derived feedstocks are compatible with existing refinery processes without causing operational disruptions.
-Economic Viability: Balancing the costs of biomass processing and integration with the potential economic benefits.
-Environmental Impact: Addressing the environmental implications of biomass integration, including emissions and sustainability.
-Infrastructure Adaptation: Modifying existing refinery infrastructure to accommodate biomass feedstocks without significant capital investment.

Proposed Solutions:
-Advanced Hydroprocessing Techniques: Utilizing mild hydro treatment and esterification to make biomass-derived feedstocks compatible with refinery processes.
-Cost-Effective Precipitation Methods: Implementing efficient lignin extraction processes to reduce costs and improve economic viability.
-Green Hydrogen Utilization: Leveraging green hydrogen produced from electrolysis to minimize environmental impact.
-Strategic Infrastructure Investments: Identifying key areas for infrastructure adaptation to facilitate seamless integration of biomass feedstocks.
 
This workshop underscored the importance of collaborative efforts in advancing biomass integration, paving the way for a more sustainable and economically viable future in the refining industry.

To listen to the workshop: 
 
We’d like to share our thanks with our speakers for their insights:
Joseph Samac - Valorization of Forestry Side-stream

Ana Indes Torres - Biomass integration in Refineries with a Focus on System-Level Modeling and Optimization of Integration Strategies

Michael Reynolds - Advances in Catalysts for Feeds that Contain Blends of Seed and Tallow Oils

Nicholas Carlson Refinery Integration Anaysis: Pathways, Challenges, and Opportunities

Mike Griffin Producing Hydrocarbon Fuels from Woody Biomass via Catalytic Pyrolysis and Refinery Hydrotreating

Ryan Lively Separation of Bioderived Compounds Using Membrane Technology

RBI would love to hear from you on future topics you would like to hear us cover. Share your feedback with Executive Director Carson Meredith.
 

Following a nationwide search, Julia Kubanek, vice president for Interdisciplinary Research at Georgia Tech, has named Beril Toktay as the executive director of the Brook Byers Institute for Sustainable Systems (BBISS). Toktay has served as BBISS interim executive director since September 2022.

“As interim executive director, Beril has built the BBISS community, broadened its scope, and developed new programming to grow cross-disciplinary collaboration, community-engaged research, and entrepreneurship,” Kubanek said. “Faculty and students from the liberal arts, social sciences, design, business, computing, and fundamental science are engaging with BBISS in greater numbers, complementing our engineering community’s involvement. These are areas of strength at Georgia Tech that will help amplify the impact of BBISS.”

Toktay is professor of operations management, the Brady Family Chair, and Regents' Professor at the Scheller College of Business. She is an internationally recognized sustainable operations management scholar whose work has been recognized with multiple best paper awards. She is a Distinguished Fellow of the INFORMS Manufacturing & Service Operations Management (MSOM)Society. Through initiatives such as the Drawdown Georgia Business Compact, she has helped translate research insights into actionable business initiatives while fostering regional economic development.

Her academic leadership includes serving as department co-editor for “Health, Environment, and Society” for MSOM, area editor for “Environment, Energy, and Sustainability” at Operations Research, and special issue co-editor on “Business and Climate Change” for Management Science, as well as “Environment” for MSOM. She serves on the board of the Alliance for Research on Corporate Sustainability and the board of directors of the New York Climate Exchange.

Toktay has been instrumental in advancing sustainability at Georgia Tech, serving as founding faculty director of the Ray C. Anderson Center for Sustainable Business, co-architect of the Serve-Learn-Sustain initiative, and co-chair of the Sustainability Next Institute Strategic Plan Implementation Task Force. Her commitment to Ph.D. student success earned her the 2018 Georgia Tech Outstanding Doctoral Thesis Advisor Award. She also co-developed the Carbon Reduction Challenge, an award-winning interdisciplinary, co-curricular program that engages undergraduate students in climate intrapreneurship.

Toktay holds a Ph.D. in operations research from Massachusetts Institute of Technology, an M.S. in industrial engineering from Purdue University, and a B.S. in industrial engineering and mathematics from Boğaziçi University. She joined Georgia Tech in 2005 after serving as faculty at INSEAD business school in Fontainebleau, France.

Since assuming the interim role, Toktay has significantly strengthened BBISS by expanding the faculty leadership team, securing additional funding, establishing seed grant programs that have benefited over 100 researchers across all Colleges, and transforming the Center for Serve-Learn-Sustain into the Center for Sustainable Communities Research and Education.

"Energy and sustainability continue to be top Georgia Tech research priorities, for which we will need new funding strategies," said Tim Lieuwen, executive vice president for Research. "Philanthropy and business partnerships will grow in importance in the coming years. Beril has considerable experience and vision for maximizing these partnerships, which will serve BBISS and the Institute well into the future."

The Brook Byers Institute for Sustainable Systems is one of Georgia Tech’s interdisciplinary research institutes. The vision of BBISS is to grow and mobilize Georgia Tech’s knowledge assets — people and research — to create a sustainable future for all. BBISS is a key partner in the implementation of Georgia Tech’s Sustainability Next 2023-2030 Strategic Plan, a consensus road map to advance Georgia Tech’s vision to address the biggest local, national, and global challenges of our time. BBISS relentlessly serves the public good, catalyzes high-impact research, develops exceptional leaders, and cultivates partnerships that translate knowledge into practice.

"I'm honored to lead BBISS and build on the momentum we've created to date,” Toktay said. “Our vision is to maximize the collective impact of Georgia Tech's remarkable sustainability research community across all colleges and disciplines. By catalyzing collaborative research and connecting our faculty with key external partners and communities, we are positioning Georgia Tech to be a global thought leader in sustainability and to drive meaningful solutions to some of our most pressing environmental and social challenges."

The campus community is invited to a reception celebrating Toktay's appointment on Thursday, May 1, 2025, at 4:30 p.m. at the Collective Food Hall in the Coda building. Contact Susan Ryan for details.

Over 5,000 people attended Georgia Tech's Celebrate STEAM event on March 8, which showcased more than 60 demonstrations in science, technology, engineering, art, and mathematics.

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The Georgia Tech Renewable Bioproducts Institute (RBI) hosted the APPTI Net Zero Workshop on Decarbonizing the Pulp & Paper Sector during the second week of August.

Over 40 participants from more than 20 organizations participated in the event aimed to educate the pulp, paper, and tissue manufacturing community on current decarbonization technologies ready for immediate deployment, while also exploring the investments needed for future breakthrough innovations. 

The workshop kicked off with an overview of APPTI by Chris Luettgen, managing director of APPTI and RBI's lead for process efficiency and intensification of pulp paper packaging & tissue manufacturing. Presentations and discussions revolved around three focus areas for decarbonization--Carbon Capture and Beneficial Use; Biogas Generation from Waste Streams; and Lime Kiln Alternatives to Fossil Fuels. Presenters and panelists consisted of members from the Department of Energy’s Industrial Efficiency and Decarbonization Office (IEDO), academia (North Carolina State University, Abo Academy, University of Toronto, University of Minnesota), and industry (Veolia, Valmet, Metso, FPInnovations, Nexight, Beck and Associates). 

RBI’s  Carson Meredith, Valerie Thomas, and Cyrus Aidun were among the presenters. Meredith presented his research on felt design to prevent re-wet, while Thomas’ talk was on the topic, life cycle assessment: meeting policy benchmarks for decarbonization, and Aidun presented his work on multi-phase forming.  

The workshop concluded with the net zero committee discussing key takeaways from the workshop and potential for a life cycle assessment on the paper industry.

“The outcome of this two-day workshop is a strong feeling about the work RBI and APPTI are doing for the industry. The feedback I received was all very positive,” said Luettgen.

Amino acids are essential for nearly every process in the human body. Often referred to as ‘the building blocks of life,’ they are also critical for commercial use in products ranging from pharmaceuticals and dietary supplements, to cosmetics, animal feed, and industrial chemicals. 

And while our bodies naturally make amino acids, manufacturing them for commercial use can be costly — and that process often emits greenhouse gasses like carbon dioxide (CO2).

In a landmark study, a team of researchers has created a first-of-its kind methodology for synthesizing amino acids that uses more carbon than it emits. The research also makes strides toward making the system cost-effective and scalable for commercial use. 

“To our knowledge, it’s the first time anyone has synthesized amino acids in a carbon-negative way using this type of biocatalyst,” says lead corresponding author Pamela Peralta-Yahya, who emphasizes that the system provides a win-win for industry and environment. “Carbon dioxide is readily available, so it is a low-cost feedstock — and the system has the added bonus of removing a powerful greenhouse gas from the atmosphere, making the synthesis of amino acids environmentally friendly, too.”

The study, “Carbon Negative Synthesis of Amino Acids Using a Cell-Free-Based Biocatalyst,” published today in ACS Synthetic Biology, is publicly available. The research was led by Georgia Tech in collaboration with the University of Washington, Pacific Northwest National Laboratory, and the University of Minnesota.

The Georgia Tech research contingent includes Peralta-Yahya, a professor with joint appointments in the School of Chemistry and Biochemistry and School of Chemical and Biomolecular Engineering (ChBE); first author Shaafique Chowdhury, a Ph.D. student in ChBE; Ray Westenberg, a Ph.D student in Bioengineering; and Georgia Tech alum Kimberly Wennerholm (B.S. ChBE ’23).

Costly chemicals

There are two key challenges to synthesizing amino acids on a large scale: the cost of materials, and the speed at which the system can generate amino acids.

While many living systems like cyanobacteria can synthesize amino acids from CO2, the rate at which they do it is too slow to be harnessed for industrial applications, and these systems can only synthesize a limited number of chemicals.

Currently, most commercial amino acids are made using bioengineered microbes. “These specially designed organisms convert sugar or plant biomass into fuel and chemicals,” explains first author Chowdhury, “but valuable food resources are consumed if sugar is used as the feedstock — and pre-processing plant biomass is costly.” These processes also release CO2 as a byproduct.

Chowdhury says the team was curious “if we could develop a commercially viable system that could use carbon dioxide as a feedstock. We wanted to build a system that could quickly and efficiently convert CO2 into critical amino acids, like glycine and serine.”

The team was particularly interested in what could be accomplished by a ‘cell-free’ system that leveraged some process of a cellular system — but didn’t actually involve living cells, Peralta-Yahya says, adding that systems using living cells need to use part of their CO2 to fuel their own metabolic processes, including cell growth, and have not yet produced sufficient quantities of amino acids.

“Part of what makes a cell-free system so efficient,” Westenberg explains, “is that it can use cellular enzymes without needing the cells themselves. By generating the enzymes and combining them in the lab, the system can directly convert carbon dioxide into the desired chemicals. Because there are no cells involved, it doesn’t need to use the carbon to support cell growth — which vastly increases the amount of amino acids the system can produce.”

A novel solution

While scientists have used cell-free systems before, one of the necessary chemicals, the cell lysate biocatalyst, is extremely costly. For a cell-free system to be economically viable at scale, the team needed to limit the amount of cell lysate the system needed.

After creating the ten enzymes necessary for the reaction, the team attempted to dilute the biocatalyst using a technique called ‘volumetric expansion.’ “We found that the biocatalyst we used was active even after being diluted 200-fold,” Peralta-Yahya explains. “This allows us to use significantly less of this high-cost material — while simultaneously increasing feedstock loading and amino acid output.”

It’s a novel application of a cell-free system, and one with the potential to transform both how amino acids are produced, and the industry’s impact on our changing climate. 

“This research provides a pathway for making this method cost-effective and scalable,” Peralta-Yahya says. “This system might one day be used to make chemicals ranging from aromatics and terpenes, to alcohols and polymers, and all in a way that not only reduces our carbon footprint, but improves it.”

 

Funding: Advanced Research Project Agency-Energy (ARPA-E), U.S. Department of Energy and the U.S. Department of Energy, Office of Science, Biological and Environmental Research Program.

DOI: 10.1021/acssynbio.4c00359

The TAPPI Student Chapter hosted a career fair on Thursday, September 12 at the Georgia Tech Renewable Bioproducts Institute. With nearly 100 students in attendance, the event provided an excellent opportunity for students as well as professionals in the pulp and paper industry, to connect, network, and explore career opportunities. The fair attracted 45 representatives from 15 leading companies in the industry who offered internships, full-time and co-ops for both graduates and undergraduates. 

“The TAPPI Student Chapter Career Fair was an incredible opportunity for students to engage directly with industry leaders, explore diverse career paths, and secure valuable internships and job offers. The enthusiasm and participation from both students and companies truly highlighted the strength and potential of our future workforce,” said Chris Luettgen, faculty advisor of the TAPPI Student Chapter and the initiative lead for process efficiency & intensification of pulp, paper packaging, and tissue manufacturing at the Renewable Bioproducts Institute. 

Georgia Forestry Association members receive Georgia Forestry Magazine four times per year. The magazine brings together writers and leaders from the Georgia Forestry Association, Georgia Forestry Commission, and Georgia Sustainable Forestry Initiative. The magazine’s dynamic content is focused on keeping its audience connected to resources and empowered to make good decisions about their forestland asset.

In the Summer 2024 issue, the magazine has featured the Georgia Tech Renewable Bioproducts Institute and its faculty researchers Anthony J. “Bo” Arduengo, professor of practice in the School of Chemistry and Biochemistry, Matt McDowell, Carter N. Paden, Jr. Distinguished Chair and associate professor in the School of Materials Science and Engineering, and Meisha Shofner, professor in the School of Materials Science and Engineering. The feature titled ‘The Green Gusher: How Wood-Based Innovations Are Revolutionizing Sustainability and Technology,’ was written by John Casey and discussed how wood-based innovations are revolutionizing sustainability and technology in the forestry industry and included Georgia Tech’s forestry in focus video that included interviews with the three researchers.

Whether it’s developing new products, reducing costs, or increasing accessibility, innovations in manufacturing stand to improve the lives of companies and consumers alike. Georgia Tech recently took another step toward ensuring those innovations make it from lab to market with the launch of a Modular Pilot Scale Roll-to-Roll Manufacturing Facility. 

“As researchers develop new materials, one of the key aspects we’re missing is how to make them at scale. This is a major oversight because if we can’t make them at scale, we can’t transition from basic research to commercialization,” said Tequila Harris, a professor in the George W. Woodruff School of Mechanical Engineering. “With this new facility, we can prove our discoveries beyond lab-scale studies — and can go from materials innovation to product development at scale.”

Led by Harris, the new facility is the result of a partnership between the Georgia Tech Manufacturing Institute(GTMI), the Strategic Energy Institute, and the Woodruff School. As a pilot facility, it will serve as a testbed for scaling up manufacturing research open for Georgia Tech researchers as well as academic, government, and industry partners around the world.

“The larger vision I see at Georgia Tech involves innovation in manufacturing for large-scale industries,” said Georgia Tech’s Interim Executive Vice President for Research Tim Lieuwen at the facility’s unveiling event on Sept. 19. “It’s crucial that we’re innovating in basic science and technology, but we also need to be innovating in large-scale manufacturing.”

Roll-to-roll (R2R) manufacturing transforms flexible rolls of substrate materials, such as paper, metal foils, and plastics, into more complex, transportable rolls upon coating the surface with one or more fluids, such as inks, suspensions, and solutions, which are subsequently dried or cured on the base substrate. Its high yield and efficiency make R2R an ideal method for the sustainable, large-scale production of components for solar cells, batteries, flexible electronics, and separations — all industries that have expanded in Georgia in recent years.

“As a state institution, we’re ultimately here to serve our state,” said Lieuwen, who is also Regents’ Professor and David S. Lewis Jr. Chair in the Daniel Guggenheim School of Aerospace Engineering. “We’re seeing Georgia emerge as the national leader in terms of recruiting corporate investments in this space and in industries that will be served by this facility.”

Roll-to-Roll Innovations

The R2R process is similar to the production of newspapers, where a large roll of blank paper goes through a series of rollers printing text and photos. “The roll-to-roll aspect is the process of using a specialized tool to force fluid onto a moving surface,” says Harris. It’s one of the fastest-growing methods for producing thin film materials — photovoltaics used in solar cells, transistors in flexible electronics, and micro-batteries, for example — at a large scale. 

Harris’s group works to develop novel manufacturing tools, with a particular focus on understanding and improving the dynamics of thin film manufacturing to increase efficiency and minimize waste. Her group is particularly interested in slot die coating, an R2R technique where a liquid material is precisely deposited onto a substrate through a narrow slot. With the new pilot facility, researchers like Harris will be able to take their work to the next level.

“Slot die coating on a roll-to-roll can handle the broadest viscosity range of most coating methods. Therefore, you can process a lot of different materials very quickly and easily,” says Harris. “It’s one of the fastest-growing technologies in the U.S. — and currently, this is the most advanced modular pilot scale facility at an academic university in the United States.”

“Georgia Tech is way ahead of the curve in terms of our facilities,” says GTMI Executive Director and Regents’ Professor Thomas Kurfess. “This will grow our capability in the battery area, membranes, flexible electronics, and more to allow us to support the development of new technologies.”

“As technologies around cleantech continue to advance at an unprecedented pace, pilot manufacturing facilities provide a critical bridge between innovative benchtop research and commercial-scale production and manufacturing,” says Christine Conwell, interim executive director of the Strategic Energy Institute. “We are excited about the opportunities this R2R facility will provide to the Georgia Tech energy community and our industry partners.”