The aviation industry is under increasing pressure to reduce its carbon footprint as global concerns about climate change intensify. With air travel contributing a significant portion of global greenhouse gas emissions, finding sustainable solutions has become a top priority for airlines, manufacturers, and regulators alike.
The rise of Sustainable Aviation Fuel (SAF) is seen as a promising development. However, SAF currently accounts for just 0.5 percent of global fuel consumption in aviation, and scaling its production presents a major challenge. While SAF remains a critical component of decarbonising the skies, the industry must look beyond fuel alone.
Recent investments, like the FAA’s US$291 million commitment to SAF and low-emission technologies, signal hope for the industry’s future. However, SAF still is far below the industry’s needs.
“Waste-based SAFs face significant barriers. The availability of feedstock is limited, and there’s competition for resources. Processing these fuels is also complex and costly,” Nico den Ouden, Chief Innovation Officer at Gen Phoenix, said.
“We believe sustainability needs to be addressed from multiple angles. While SAFs address fuel emissions, sustainable practices should extend beyond fuel sources.
“Our focus is on reducing aircraft weight with innovative recycled seating materials, which are up to 45 percent lighter than traditional options. This leads to fuel savings and reduced environmental impact.”
From process to placement
As the aviation sector continues to evolve, the key to reducing its carbon footprint lies in balancing three factors: price, performance, and planet.
“For any solution to make a significant impact, it must be economically viable, meet performance and safety standards, and deliver substantial environmental benefits. SAF offers immediate emissions reductions, but its scalability and cost remain challenging,” den Ouden explained.
“Meanwhile, advanced materials like ours, and emerging technologies like electric and hydrogen-powered aircraft offer long-term potential. Ultimately, the solutions that excel in all three areas will shape the future of sustainable aviation.”
Gen Phoenix’s recycled leather fibre boasts an 83 percent lower carbon footprint than traditional leather.
By combining materials like Gen Phoneix’s with SAF and other clean technologies, airlines can significantly enhance their sustainability.
“Our production process has an up to 86 percent lower carbon footprint than traditional leather production, and we recycle 95 percent of the water we use through an in-house recycling plant. Plus, we power our operations with 100 percent renewable electricity sourced from wind energy,” den Ouden explained.
“The production of SAF is energy-intensive and resource-competitive. Electric and hydrogen-powered aircraft offer alternatives, but each comes with its own challenges, such as energy storage and infrastructure development. That’s why we believe material innovation is key.”
Proof of concept
One notable collaboration is with DOY Design, where Gen Phoenix supplied their low-carbon leather for Heart Aerospace’s ES-30 hybrid-electric aircraft.
“This partnership is a great example of how our recycled materials can support new, sustainable aviation technologies. We’re proud to contribute to projects that push the industry toward a more sustainable future,” den Ouden highlighted.
“We’re partnering with airlines, manufacturers, and regulatory bodies to scale our solutions and bring about real change. The industry is evolving rapidly, and we’re committed to ensuring our materials not only meet current standards but exceed future sustainability expectations.”
Circular process
The focus on materials isn’t just about reducing weight or fuel usage; it’s about adopting circular economy principles.
“Our latest innovation, Helios, is a closed-loop system that transforms end-of-life aircraft seat covers into new, fully recyclable materials. For a typical airline with 180 aircraft, this can prevent over three tonnes of landfill waste per year,” den Ouden outlined.
Gen Phoenix’s efforts are paying off. More than 250 airlines are now using their recycled leather, and feedback from partners has been overwhelmingly positive.
“Aviation materials need to meet stringent safety, durability, and regulatory requirements. Proving that recycled materials can meet or even exceed these standards is a rigorous process. We work closely with our partners to ensure our materials meet the highest standards, and we continue to invest in research and development to push the boundaries of what recycled materials can achieve,” den Ouden outlined.
“But just as important, they value the environmental benefits. Using our recycled leather helps airlines achieve their sustainability targets by reducing waste and lowering emissions.”