M&I Materials is seeking to use open innovation to identify sustainable alternatives to fossil-derived hydrocarbon feedstocks for use in the manufacture of speciality vacuum greases. Selected alternative feedstock solutions will be trialled in pilot studies within M&I’s current vacuum grease manufacturing process, with the possibility of further adoption upon successful trials.


M&amp;I Materials Ltd is a small, family-owned UK manufacturer producing several niche products, including the Apiezon range of speciality vacuum greases and oils. These are currently manufactured using petroleum jelly, processed via vacuum distillation. With a view to sustainability and long-term resilience, the company seeks to identify alternative raw materials that align with increasing demand for greener solutions from customers and the market at large. Applications extend across sectors including cryogenics, food production, laboratory equipment, and advanced sealing solutions.

Background

The production of speciality vacuum greases and oils has traditionally relied on fossil-derived hydrocarbons due to their favourable molecular structure, thermal stability, and vacuum performance. However, increasing regulatory pressure, supply chain volatility, and strong market demand for sustainable alternatives are driving the need for non-fossil feedstocks. M&amp;I Materials seeks scalable, sustainable, and technically viable raw materials that can replace fossil-derived inputs in its Apiezon product range. The aim is to identify alternative feedstocks capable of delivering the high-performance characteristics required for grease in vacuum applications, focusing on vapour pressure, low outgassing and low toxicity with current manufacturing processes, the performance of which will be validated through trials.
Currently, petroleum jelly is used as the feedstock for multiple products, typically made up of a mixture of long-chain hydrocarbons. New feedstocks will be evaluated through exploring their potential for producing the required fractions and meeting end-product specifications. New feedstocks may not require processing in the same manner and M&amp;I is open to discussions for other options. Improving efficiency is a key opportunity, as the current process leaves a significant proportion of material unused.
Possible feedstock solutions may originate from, but not limited to:
<ul>
<li>Fractions of a Fischer-Tropsch process between oils and waxes</li>
<li>Material produced after converting recycled plastics into hydrocarbon oils/waxes</li>
<li>Any source of a complex mixture of long-chain hydrocarbons found in a semi-solid state upon manufacturing</li>
<li>Bio-based feedstocks or wastes to include oils</li>
</ul>

The Challenge

The solution must/should:
<ul>
<li>20 kg minimum quantity to process the materials through our current processes for trial work. Happy to discuss quantities as little as 1kg range and plan for scale-up in the near future.</li>
<li>Be available in sufficient volumes to support scale-up. Annual requirement (when scaled up and commercial): on the tonne scale of raw material (not an immediate requirement but we should discuss how the supply of raw material could be met).</li>
<li>Be of similar constitution to petroleum jelly (semi-solid or grease/oil-compatible under ambient conditions with high carbon chain lengths)</li>
<li>Proposed feedstock should allow us to produce vacuum greases specified below</li>
<li>Possess low toxicity</li>
<li>Material should be free from undesirable impurities (moisture, sulphur compounds)</li>
</ul>
Target Characteristics of Finished Product (for Reference Only)
To assist solution providers in understanding the requirements, the following are typical characteristics of the finished Apiezon product. These are provided for reference only, to help inform the choice and suitability of proposed feedstocks. Solution providers are not expected to manufacture the final product, but should consider whether their feedstock, after processing, could enable these outcomes:
<ul>
<li>Physical State: Semi-solid at room temperature (similar to petroleum jelly)</li>
<li>Colour: White to pale yellow (minimal colouration preferred)</li>
<li>Odour: Odourless or very faint hydrocarbon odour</li>
<li>Vapour Pressure: &le;?10?? Torr at 20?&deg;C (e.g., Apiezon AP100 achieves &lt;?7.0&times;10?&sup1;&sup1; Torr at 20?&deg;C)</li>
<li>Volatility: Low, to minimise outgassing in high vacuum systems</li>
<li>Chemical Inertness: Non-reactive with stainless steel, aluminium, elastomers, and other common materials of construction</li>
<li>Purity: Free from moisture, sulfur compounds, and volatile residues</li>
</ul>
Viscosity, Pour Point, Molecular Weight Distribution to match or better Apiezon L grease.

Functional Requirements

The solution should:
<ul>
<li>Avoid introducing halogens, silicones, or reactive groups unless justified by performance benefits</li>
<li>The aim is to maintain or enhance key product properties, focusing on vacuum performance (including outgassing and thermal stability), lubricity, and extended shelf life with reliable storage stability.This will be determined through trials on the final product.</li>
<li>Benchmark data from Apiezon products will guide acceptable performance thresholds (e.g., Apiezon L Grease offers ultra-high vacuum capability without halogens or silicones)</li>
</ul>

Technical Requirements

The solution must/should:
<ul>
<li>Remain non-reactive and safe under manufacturing and storage conditions</li>
<li>Comply with regulations such as REACH and RoHS.</li>
<li>Be free from environmental or operator hazards such as:&nbsp;Corrosiveness,&nbsp;Strong odours,&nbsp;Toxic volatile components and&nbsp;Particulate generation</li>
</ul>

Operating Conditions

The solution must/should not:
<ul>
<li>Contain or require heavy metals, halogenated additives, or persistent organic pollutants (POPs)</li>
<li>Rely on feedstocks that drive deforestation</li>
<li>Require complex, multi-step hazardous preprocessing involving toxic solvents</li>
<li>Display strong colouration or odours that impact the final product&rsquo;s use in commercial environments</li>
</ul>
Use supply chains with unreliable traceability or low sustainability credentials

Out of Scope

<ul>
<li>Target unit costs are to be like petroleum jelly costs (i.e. &lt;&pound;15 kg) however all pricing can be discussed down the line.</li>
<li>Specific benchmark pricing can be provided at a later stage under NDA.</li>
</ul>

Cost Requirement

Successful applicants will:
<ul>
<li>Be invited to pitch their solutions to M&amp;I Materials Ltd</li>
<li>Have the opportunity to collaborate on real-world trials using the company&rsquo;s existing infrastructure</li>
<li>Benefit from potential supply contracts if trials are successful</li>
<li>Receive: Technical support during the trial phase, access to specialist knowledge and product benchmarks, and potential support from Innovate UK Business Connect (e.g., investment readiness, networking, funding)</li>
</ul>
Solutions that meet requirements could be adopted across other M&amp;I product lines or by partners in related industries (e.g., semiconductors, cryogenics, clean energy labs)

Rewards & Market Opportunity

<ul>
<li>Launch of the Competition: 10 November 2025</li>
<li>Deadline for applications: 19 December 2025</li>
<li>Selection and notification of finalists: 26 &ndash; 30 January 2026</li>
<li>Date of Pitch Day: w/c 16th February 2026</li>
</ul>
Pitch outcome communicated: w/c 2nd March 2026

Timescales

Entrants to this competition must be:
<ul>
<li>Established businesses, academic institutions, start-ups, SMEs, or individual entrepreneurs</li>
<li>UK based or have the intention to set up a UK base</li>
</ul>
Applications will be assessed on:
<ul>
<li>Relevance to the defined challenge</li>
<li>Benefit of implementation</li>
<li>Feasibility/economic viability</li>
<li>Innovative nature</li>
<li>Ability to launch in line with expected timescales</li>
<li>Credibility of applicant company</li>
<li>Coherence of the proposed business model</li>
<li>Development potential</li>
<li>Maturity of the solution</li>
</ul>
Suitability for the intended geographic market

Eligibility & Assessment Criteria

Existing background IP associated with a potential solution will remain with Solution Provider(s). Where any new IP generation is envisaged, it will be subject to the mutual IP agreement of the solution provider(s) and challenge holder.
Any commercial deployment of a transferred solution or newly developed solution, through licensing, joint venture, partnership, or direct investment, will be subject to the commercial agreement between the solution provider(s) and challenge holder.
Where necessary, a non-disclosure agreement (NDA) may be signed to uphold confidentiality in the engagement between the solution provider(s) and challenge holder. (This would be expected to be after company selection, it is suggested that details of IP be not disclosed, focus on the outcomes of the technology proposed).
Innovate UK and Innovate UK Business Connect do not take any share of IP ownership or enter commercial ventures through the iX programme.

IP & Potential Commercial Route

The application form for this challenge will require applicants to provide company information and answer 3 questions - Idea Summary, Technology Readiness and Intellectual Property &ndash; each with a limit of 300 words.
Optionally, up to 3 supporting documents can be attached to the application. We recommend that supporting documents are limited to those which are directly relevant to the application. Please note that applications with no supporting document will not receive any penalty in assessment. Supporting documents which the Assessment Panel deems to be superfluous may be disregarded. Examples of useful additional documents include product images or short specification sheets, slide decks detailing the solution and/or company background, or solution case studies.
We recommend that you complete the application form in Google Chrome as other browsers may have compatibility issues. The application form does not need to be completed in one session and can be saved for future edits. Please ensure that you toggle &ldquo;Stage Complete&rdquo; for each section before submission. Note that you will no longer be able to edit your application once you have clicked &ldquo;Submit Idea&rdquo; at the bottom of the Summary page.

Application & Technical Guidance

By submitting an application to this Innovation Exchange (iX) challenge, you acknowledge and agree that the information you provide will be shared with Innovate UK Business Connect and the challenge holder for the purposes of assessment and selection. All information submitted will be handled in confidence and shared only with those involved in the assessment and selection process under appropriate confidentiality expectations.
Please consider the level of detail you share in your submission to ensure it aligns with your own internal confidentiality or disclosure policies.
A selected panel of assessors will review and score your application. The panel of assessors will meet and agree a consensus score. Successful solutions will be selected by the challenge holder. Success will be based upon total consensus scores, a portfolio approach and capacity within the challenge holder&rsquo;s organisation to carry out the projects.
For more information on how Innovate UK Business Connect handles personal data, please refer to our&nbsp;<a href="https://iuk-business-connect.org.uk/privacy-policy/">Privacy Policy</a>.

Sustainable Alternative Raw Materials to Fossil Derived Hydrocarbons for the Manufacture of Speciality Vacuum Greases

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Opportunity

Challenge opens

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Background

This challenge is brought to you by:

Sustainable Alternative Raw Materials to Fossil Derived Hydrocarbons for the Manufacture of Speciality Vacuum Greases