At Bio-SIP™, innovation never stands still. Our mission has always been to rethink how buildings are made—making construction faster, cleaner, and far more sustainable. With our recent progress in testing, certification, and production planning, we’re excited to share how the Bio-SIP™ system and our emerging micro-factory are set to reshape how and where sustainable buildings are made.
A Building System Ready for the Next Step: Bio-SIP micro factories
The Bio-SIP™ (Bio-based Structural Insulated Panel) has been in development for a few years and has now reached a significant stage in readiness for market. Combining 100% post-consumer recycled plastic waste with natural fibres such as hemp and flax, it creates a strong, lightweight, and high-performing building panel. The result is a construction material that not only reduces embodied carbon but also diverts waste from landfill—turning a global environmental challenge into a valuable resource.
We’ve already proven Bio-SIP™ capabilities in the field through completed buildings and independent testing. Our panels deliver a thermal conductivity of 1.377 m²K/W at 100 mm thickness, and a 300 mm panel achieves a U-value of just 0.11 W/m²K, meeting PassivHaus standards. This level of performance demonstrates that exceptional energy efficiency can go hand-in-hand with sustainable materials.
Tested, Proven, and Moving Toward Certification
Recent testing milestones have further validated the system’s performance and safety. Our reaction-to-fire testing (EN 1365-1) achieved 52 minutes performance, and reaction-to-fire classification at the BRE in Watford confirmed a Class E rating—an improvement over conventional SIP systems that typically achieve only Class F.
These results form a crucial part of our ongoing BBA certification process, which is now well underway. Achieving certification will open the door for Bio-SIP™ to move beyond unregulated buildings—such as garden rooms, extensions, and leisure buildings—into the fully regulated construction sector, including residential and commercial projects.
The Rise of the Bio-SIP micro factories
While Bio-SIP™ is an advanced product in its own right, its real potential lies in how it can be manufactured and deployed. Traditional construction supply chains rely on large centralised facilities, heavy transport, and fragmented processes. Bio-SIP™ changes that with a micro-factory model—a decentralised, scalable approach designed for local production and local impact.
Each micro-factory is a compact, efficient production unit capable of manufacturing Bio-SIP™ panels and assembling building kits. The facilities are modular in nature, allowing them to be set up quickly in regional locations close to end markets. This model dramatically reduces transport emissions, supports local employment, and allows materials to be sourced and processed locally.
A typical Bio-SIP™ micro-factory can be established with an initial investment of around £250,000–£400,000, depending on size and automation. Once operational, each facility can deliver up to £1–1.5 million in annual turnover, with an expected return on investment within 2–3 years. This makes it not only an environmentally responsible model but also a sound and scalable business opportunity for regional partners.
Local Crops, Local Production, Local Value
By turning waste into a valuable building resource, Bio-SIP™ micro-factories contribute to regional resilience and sustainability. They provide skilled jobs in green manufacturing and offer local builders and architects access to high-performance, low-carbon materials made right on their doorstep.
Building Smarter, Faster, and Cleaner with Bio-SIP micro factories
The performance advantages of Bio-SIP™ are matched by its speed of assembly. Each panel combines structure, insulation, and airtightness in one product, simplifying the build process and significantly reducing time on site. For homeowners, developers, and modular housing providers, this means faster delivery, fewer trades, and less disruption.
Because panels are precision-engineered in a factory environment, waste is minimised, and quality control is consistent. Combined with our thermal and fire performance results, Bio-SIP™ buildings offer long-term benefits including lower energy bills, greater comfort, and minimal maintenance.
A Scalable Pathway to Sustainable Growth
The beauty of the micro-factory model lies in its scalability. Instead of one massive central plant, the Bio-SIP™ network can grow organically—region by region, project by project. Each new factory contributes to national sustainability goals while serving its local community.
In practice, this means that an architect in Manchester, a housing developer in Bristol, or a modular builder in Glasgow could all access locally made Bio-SIP™ products without relying on long-distance shipping. As energy and resource costs continue to rise, localised production becomes not only sustainable but also economically essential.
Creating Opportunities for Collaboration
Bio-SIP™ is now entering an exciting phase of partnership development. We’re engaging with potential licensees, regional authorities, and sustainability-focused investors who recognise the potential of the micro-factory network. Each partner has the opportunity to be part of a national shift toward low-carbon manufacturing and sustainable building systems.
For local councils and regeneration bodies, the Bio-SIP™ micro-factory offers a pathway to green skills training, job creation, and carbon reduction within their region. For businesses, it presents a route to participate in the rapidly growing sustainable construction sector with a proven, scalable product.
Looking Ahead with Bio-SIP micro factories
With BBA certification progressing, successful fire testing completed, and the micro-factory model moving into pilot stage, Bio-SIP™ is positioned to become a cornerstone of the UK’s low-carbon construction landscape.
Our goal for the coming year is to establish the first operational micro-factory to demonstrate the full potential of localised manufacturing. This will act as a blueprint for replication across the UK and internationally, showing how sustainable construction can be achieved without compromise.
A New Era for Construction
The building industry is facing a defining moment. The pressure to reduce carbon emissions, manage waste responsibly, and deliver affordable, efficient buildings has never been greater. Bio-SIP™ meets all three challenges head-on—with a product and a manufacturing model that together redefine what sustainable construction looks like.
By combining cutting-edge material science, circular economy principles, and regional manufacturing, Bio-SIP™ isn’t just changing how buildings are made—it’s changing how the construction industry itself can operate.
As we move into this next chapter, we’ll continue sharing updates on our certification journey, pilot projects, and partnerships. The Bio-SIP™ story is about more than panels—it’s about people, places, and a future built smarter, together.
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