Sustainable Innovation With Alabama Biomanufacturing Labs

Welcome to Alabama Biomanufacturing Labs’ inaugural newsletter! This newsletter is a way for our organization to share key innovations in the biomanufacturing industry and highlight companies in our cohort that are driving those trends. ABL was established through a competitive award from Innovate Alabama's tax credit program. The $1.2m program drives innovation and economic growth in the state through the work of three core partners:

We are expanding biomanufacturing in rural areas by supporting emerging startups with technical, entrepreneurial, commercial, legal, and regulatory services from key program stakeholders. We are currently supporting a cohort of nine companies, representing Alabama ecosystems like Opelika, Auburn, Tuskegee, Troy, and Dothan.

Have you ever thought about where your trash actually goes? What if the coffee cup you threw away yesterday could come back as part of your furniture, or if your old clothes could be reborn as new outfits? Today, we know more than ever about the dangers of waste to our environment. Microplastics are small plastic pieces measuring less than five millimeters in length, which can be harmful to terrestrial and aquatic life. They have not only been found in oceans and soil, but also in human organ tissue and even baby formula.¹ In a recent study, microplastics were detected in 8 out of 12 human organ systems, including cardiovascular, digestive, respiratory, etc. They were also observed in breastmilk, stool, and urine. It paints a grim picture of just how deeply these toxins have infiltrated our world.

Consumer sentiments are shifting toward sustainability, driving demand for eco-friendly alternatives to synthetic materials. Across the country, startups are rising to meet this challenge, transforming bio-based materials into everyday products and showing that waste can be a starting point for innovation. In ABL’s 2025 cohort, two companies, Shellulose and Forsee, are leading the way by transforming overlooked materials into sustainable solutions.²

Shellulose LLC, was founded by Dr. Symone Alexander, a chemical engineering professor at Auburn University in Alabama. The company is focused on extracting cellulose from pecan shells. Dr. Alexander has developed a method to transform these pecan shells, which are often discarded as waste in the state’s farming industry, into cellulose nanofibers. These nanofibers are biodegradable materials that can replace petroleum-based fibers used in packaging, food products, and cosmetics.³ This process also avoids the harsh chemicals often used to produce synthetic fibers, making it both safer and more environmentally sustainable. Shellulose helps reduce microplastic pollution while creating new revenue opportunities for local pecan farmers by purchasing their pecan shell waste. By doing so, Shellulose is tapping into the global cellulose fiber and nanofiber market, which is worth billions and continues to expand as industries look for renewable materials. Shellulose is already producing about 300 grams a day in the lab, and with help from NSF and DOE grants, the team is racing towards pilot-level production.

Like Shellulose, Forsee LLC shows how waste can be reimagined into valuable products, proving that sustainable innovation can take many different forms. Led by CEO Chera Howard in Prattville, Alabama, Forsee focuses on transforming processed hair fibers into bio-based, recyclable fibers designed to resist fire. By leveraging the specific properties of hair, such as its high nitrogen content and unique structure, the company has engineered a way to slow the spread of flames without relying on toxic chemicals that are often found in traditional retardant products.⁴ Forsee’s process also enhances durability, making the material useful for insulation, coatings, and mats. The impact is significant, as it provides a safer and renewable alternative while also helping reduce wildfire risks and expand the use of sustainable materials in industries like construction, aerospace, and defense. This positions Forsee at the forefront of fire-resistant material innovation, a rapidly growing area within the global safety market. With multiple patents already secured and research partnerships in place, Forsee is preparing to enter a global fire-retardant market that is projected to reach $13.5 billion by 2030.

Shellulose and Forsee may be operating in different markets, but they share a mission: take something people usually throw away and turn it into something valuable. That shared mindset has already led to collaboration, with Symone and Chera now working together to develop more fire-resistant plastics using Forsee’s fibers. Whether it is pecan shells from an orchard or hair fibers from the salon or barber shop, both companies are proving that waste can be the starting point for real innovation. They are not only cutting down on the damage caused by plastics and synthetics but are seeding the manufacturing solutions for the safer, better products of tomorrow. With ABL’s support through mentoring, business guidance, and connections to industry partners, these companies are focused on growing their work and making these sustainable solutions available for a larger population. 

In today’s world, we’re seeing more industries transform waste into something useful. These companies remind us that waste does not have to stay waste and are prime examples of how Alabama innovators are helping shape the future of sustainable materials. To learn more about ABL’s 2025 cohort, visit our website or follow us on LinkedIn. Be sure to check back in next month’s newsletter, where we will feature more startups that are pushing the boundaries here in Alabama!

Our previous newsletter is available on LinkedIn for those who missed it.

¹ National Library of Medicine & Journal of Global Health, “Detection of Microplastics in Human Tissues and Organs: A Scoping Review,” August 23, 2024. https://pmc.ncbi.nlm.nih.gov/articles/PMC11342020/

² McKinsey & Company, “Consumers care about sustainability—and back it up with their wallets,” February 6, 2023. https://www.mckinsey.com/industries/consumer-packaged-goods/our-insights/consumers-care-about-sustainability-and-back-it-up-with-their-wallets

³ MDPI & Molecules, “Conventional and Novel Strategies for Cellulose Isolation from Nut Shells: A Review,” August 7, 2025. https://www.mdpi.com/1420-3049/30/12/2486

⁴ MDPI & Polymers, “Keratinous Natural Fibres as Sustainable Flame Retardants and Reinforcements in Polymer Composites,” June 17, 2024. https://www.mdpi.com/2504-477X/8/6/230Technology isn't just about the latest gadget—it's about solving real-world problems that can genuinely improve people's lives.