The production of PHA (Polyhydroxyalkanoate) begins with the selection of feedstocks, which can include plant-based materials such as corn, sugarcane, and vegetable oils, as well as waste streams like used cooking oils, wastewater, and organic or plastic waste. Additionally, greenhouse gases like CO₂ and methane can also serve as feedstocks. The next step involves fermentation, where bacteria consume these carbon-rich feedstocks and synthesize PHAs as a form of energy storage within their cells. Once the microorganisms accumulate enough PHA, the biopolymer is extracted and purified to ensure it is ready for processing.

PHA is then transformed into various products through techniques such as injection molding, extrusion, and thermoforming. This versatility allows it to be used for a wide range of applications, including packaging, reusable items like cups and cutlery, textiles, cosmetics, medical products, and in our case discs for Ultimate & Disc Golf. In terms of end-of-life management, PHA offers multiple environmentally friendly options. It is fully biodegradable and compostable, breaking down safely in soil, freshwater, and marine environments without producing microplastics. Additionally, PHA products can be recycled or used as renewable feedstock through composting or anaerobic digestion, ensuring a sustainable, circular lifecycle that minimizes waste and reduces greenhouse gas emissions.

Biocomposites are produced using a carefully designed process that integrates sustainable feedstocks, advanced compounding technologies, and efficient manufacturing practices. The key materials include cellulose fibers and wood particles, sourced from sustainably managed forests and pulp production residues, along with crude tall oil (CTO), a byproduct of the pulping process. This renewable content ensures that no additional trees are harvested, and it avoids competition with the food chain.

The production process involves compounding these fibers and polymers, embedding the fibers evenly into the polymer matrix to enhance strength, stiffness, and mechanical performance. These compounding methods ensure excellent fiber dispersion, preventing brittleness and creating smooth, durable materials. This Biocomposite materials are processed through conventional injection molding and extrusion, making them compatible with existing machinery and molds. These techniques allow the production of a wide range of durable products.

This biocomposite is fully recyclable and can be collected, sorted, and reprocessed without significant degradation. Additionally, energy recovery is possible through incineration, with a neutral carbon footprint due to the renewable nature of the feedstocks. The process aligns with circular economy principles, integrating waste streams like label waste into products to reduce landfill use. Certified under ISO 9001 and ISO 14001 standards, our biocomposites meet stringent quality and environmental requirements, offering a sustainable, high-performance alternative to fossil-based plastics.

At Bernoulli, we are committed to sustainability and environmental responsibility. As part of this mission, we integrate GRS (Global Recycled Standard)-certified recycled plastics into the manufacturing of our disc golf discs. The GRS certification ensures that the materials we use meet rigorous environmental and social criteria, including responsible sourcing, ethical labor practices, and minimized environmental impact throughout the supply chain.

Our focus on recycled materials helps reduce waste, lower our carbon footprint, and contribute to a circular economy by giving new life to post-consumer and post-industrial plastics. Despite being eco-friendly, our discs maintain high performance and durability, offering the same precision, grip, and flexibility that players expect.

Through the use of GRS-certified recycled plastics, we not only create top-quality discs for disc golfers but also support sustainable development and demonstrate our dedication to making a positive environmental impact. Bernoulli's innovative approach to manufacturing aligns with the growing demand for sustainable products in the sports and recreation industry.