The world’s first pilot facility to convert non-recyclable waste plastic into sustainable aviation fuel (SAF) has opened in the UK. The site, operated by Clean Planet Technologies, is located at Discovery Park in Sandwich, Kent.
It is designed to tackle two major challenges simultaneously: plastic waste and aviation emissions. The UK generates around 5 million metric tons of waste plastic each year, of which roughly 80% cannot be recycled.
At the same time, global aviation consumes between 7 and 8 million barrels of jet fuel per day, with less than 1% currently coming from sustainable sources.
Thus, the new facility aims to demonstrate how hard-to-recycle plastics can be converted into a viable low-carbon fuel for aviation. The process involves heating waste plastic to turn it into a liquid, which is then refined and upgraded into SAF that meets aviation standards.
According to the company, the method can reduce lifecycle greenhouse gas emissions by more than 70% compared to conventional jet fuel.
“Our pilot facility will demonstrate this waste can be turned into a premium product with a quantifiable commercial demand,” said Dr Andrew Odjo, CEO of Clean Planet Technologies. He added that the technology could also help reduce the environmental impact of both plastic pollution and air travel.
The facility integrates several stages of the conversion process into a single system, allowing for testing, validation and further development. It is also expected to support fuel qualification under international aviation standards, with backing from the UK SAF Clearing House.
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The process begins with shredding waste plastic, followed by pyrolysis, where the material is converted into a synthetic crude oil in an oxygen-free environment. This is then purified, distilled and upgraded using hydrogen to produce an ultra-low sulphur aviation fuel.
Although these technologies already exist at commercial scale individually, the pilot aims to demonstrate their combined application for SAF production. The development comes as the UK pushes to scale up sustainable aviation fuel use.
Government targets require SAF to account for 2% of jet fuel demand, rising to 10% by 2030 and 22% by 2040. According to the company, the facility could help support these goals while advancing solutions for hard-to-recycle plastic waste.
“This pilot facility addresses two strategic challenges simultaneously: plastic waste management and aviation decarbonisation,” said Bertie Stephens, CEO of Clean Planet Group.
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