New Carbondale business looks to reduce carbon emissions in its building materials

Flora Materials, an innovative biomaterials startup based in Carbondale, is breaking new ground in sustainable construction with the development of algae-based building materials. 

The company, led by founder Natalie York, has secured an additional $1.9 million in funding through the U.S. Army’s Small Business Innovation Research (SBIR) Program to scale up its pioneering algae-based flooring tiles.

Initially awarded $250,000 in 2023 for Phase I research, the new Phase II contract focuses on scaling production to deliver durable, U.S.-sourced flooring solutions that are both functional and sustainable.

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Founded in 2023, Flora Materials operates as a research arm within West 40 Studio, a design and architecture firm in Carbondale. 

“We are excited to be here in Carbondale and to really make an impact,” York said. “We are hoping to create more jobs in Carbondale, as well — especially when we get to the manufacturing stage.” 

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She said that she began researching the product in 2021.

“We started with the idea to research building materials and eliminate the petroleum-based chemicals and replace the chemicals with a bio-based alternative,” she said. “Our projects through our grant funding is to look into vinyl products, such as flooring and interior and exterior siding.”

The company’s cutting-edge approach uses a bio-based polyurethane composite, replacing traditional petroleum-based polyvinyl chloride (PVC) materials. 

“The materials we use in construction should not only perform well, but also benefit our planet,” stated York in a press release. “We’re proving it’s possible to have beautiful, durable, and environmentally-responsible alternatives.”

Her vision is to replace standard flooring products like luxury vinyl tile (LVT) with options that are not only more sustainable, but also perform just as well. 

“We are shooting for a 90% bio-based product that will meet the USDA BioPreferred certification,” York said, ensuring that the final product not only aligns with industry standards but also supports American manufacturing. “That is what the Army is interested in because they are moving forward with their Climate Action Plan and going bio-based in the near future.”

By utilizing algae’s natural carbon-capturing abilities, Flora Materials flooring tiles aim to significantly reduce the construction industry’s carbon footprint. Current estimates suggest that traditional PVC flooring contributes over 10 million tons of CO₂ emissions annually. 

The company’s algae-based alternative not only cuts emissions, but also enhances recyclability, making it a promising solution for greener construction.

While the current focus is on flooring, it plans to explore additional applications for its algae-based biomaterials in construction.

“We will be developing the manufacturing stage at the same time as product development,” said York. “That will help us keep costs down and focus on developing a bunch of different product options.”

She said that West 40 Studio is designing a net-zero residential project in Pitkin County, in which Flora Materials’ products will be installed.

“We are going to be installing the product in a project in Pitkin County, which will help us navigate and understand how the product needs to be installed,” she said. “We will be working with local contractors in the valley to work on this net-zero project. It will really tie everything together.”

The ultimate goal of the Phase II project is to produce enough algae-based tiles to cover an 800-square-foot project, proving scalability and market readiness. With a focus on bio-content, durability, and ease of installation, Flora Materials is setting the stage for a sustainable transformation in the building industry.

For more information about the company and its products, visit floramaterials.com.