Turning our waste fat into fuel to power the green revolution

Syntech

Karen McLauchlan how he swapped the brewery business for biofuels and is helping lead the charge on sustainable green fuel.

From fryers to fuel tanks – that’s Syntech Biofuel in a nutshell.

The Kent-based renewable fuel company produces its sustainable product, Syntech ASB (advanced smart biofuel), from waste vegetable oils sourced from UK pubs, restaurants, chip shops and fast-food outlets.

And by giving waste new life, it is reducing emissions, replacing carbon fossil fuels to help halt the climate change crisis and powering some of the UK’s biggest infrastructure projects.

“Every litre we produce is fully traceable, International Sustainability and Carbon Certification (ISCC) certified, and 100% made in Britain,” said Mike. “That makes it the most practical, immediate solution for organisations who can’t afford to wait for net zero.”

Mike O’lone is Director of Environment, Sustainability and Social Impact and says the company currently makes “the most sustainable fuel available in the UK”. And as we talk about the business and its success to date, his passion for this green fuel, the team that makes it happen and the community in which it works is tangible.

“We believe in doing things differently,” he said. “We’ve not taken the easiest route and what we do is niche. But I love what we do and we’ve created an environment where people are excited to get into work in the morning.”

“Unlike imported fuels, our solution is homegrown - built for the transition, powered by UK waste, and proven to deliver.”

Mike hasn’t always been involved in the eco-fuel business. A former technical manager in the brewing industry, he was more used to looking after large-scale installations at major social and sporting outlets. When a knee operation meant taking time off, he didn’t rest up completely but took on a new mental challenge – learning the Knowledge of London, the famous and rigorous examination for prospective London cab drivers. Looking for a change of work/life balance he then took to the road as one of the capital’s cabbies.

But around 10 years ago a call from long-time friend Robert Hart – who founded Syntech along with Tom Bingham – led his career path to shift course into the world of biorefineries. Originally established as an energy-from-waste company, a change in legislation saw Syntech pivot to the world of biofuels.

The company currently has two operational facilities at Kingsnorth Industrial Estate in Grain, with a third now 80 per cent of the way to completion. A fourth site at Kingsnorth is in the advanced planning stages with ambitions to operate a further base near Grangemouth in Scotland, to feed demand in the north of the UK.

The team is also looking to ramp up output. Currently producing around a million litres per month, this is set to double by early 2026.

“Expansion and investment will see this rise to 100 million litres annually from Q4 2026,” said Mike. “We’re also looking to expand our team of around 30 staff to 200 on the back of projected growth.”

Syntech Biofuel predominately supplies to Tier 1 construction companies to power large on-site vehicles, excavators and earth movers as well as generators.

“We wanted to prove there’s no need to rely on unsustainable imports when you can build a transparent, UK sourced alternative that industry can trust.”

“But in 2022 we were recognised by National Highways to be involved with the groundbreaking Lower Thames Crossing (LTC) project, which is one that won’t use diesel, the first of its kind in the UK.”

The LTC is a new road that will connect Kent and Essex through a tunnel beneath the River Thames. In June this year the Government announced £590 million for the £9bn project describing it as the “most significant road building project in a generation” and a “national priority”.

LTC has also set targets to reduce its construction carbon emissions by 70 per cent; an ambition made possible thanks to the delivery partners’ and suppliers’ commitment to making the crossing the greenest road ever built in the UK.

Feedstock for the fuel process is sourced from across the UK. When new oil is delivered to food outlets, their used cooking oil (UCO) is also collected and taken to a hub where it is checked to ensure it meets the International Sustainability and Carbon Certification (ISCC) standard. It is then delivered to Syntech’s site, travelling the fewest miles possible compared to supplies from overseas which rack up thousands of international miles and a huge carbon impact.

After filtration, this feedstock is processed creating biofuel and by-product glycerol, which is sent to be used for animal feed or for anaerobic digestion processes. A science team based at the site conduct tests for quality control, before it is delivered to construction sites.

With a clean circular manufacturing process and generating its own energy on site, it means the plant is low in carbon intensity, which Mike says is “very unusual” for a facility of its size.

“In fact, our biofuel cuts lifecycle emissions by up to 93% compared to fossil diesel - a carbon saving you can count today.”

“In our baseline year of carbon reporting we registered 255 tonnes of CO2 for offset, which is unheard of in industrial processes,” he said. “Even in smaller industrial sites the figure would normally be in the hundreds of thousands of tonnes a year.”

And crucially, Syntech ASB is helping decarbonise energy and transport systems and transition away from fossil fuel use, helping the UK work towards the net zero 2050 target.

“We turned our backs on foreign imports of palm and soy oil – we weren’t comfortable with it; it didn’t sit right with us. The way we went cost more and Covid almost bankrupted us when the UK hospitality sector closed.

Syntech Biofuel has been working with Balfour Beatty, the contractor delivering the roads north of the Thames for the project. Last October it was signed to Balfour Beatty’s procurement framework to provide fuel for the LTC project – which will be the catalyst for expanding Syntech’s production increase. Syntech Biofuel is also involved with other major construction projects.

But Mike says social impact is equally important with Syntech creating a range of initiatives to inspire the next generation of green energy pioneers and tackle the skills crisis.

Lesson plans for local primary schools, talks at colleges and universities plus working with the University of Kent to offer placements to biochemistry students are all ways it’s working with the sector’s future leaders.

“It’s so important to be working with children and young people,” said Mike, “getting the sustainability messages across and tackling environmental anxiety very early on. It’s about incremental, consistent steps in being more aware and taking care of the planet. Everyone can play their part –many voices make a loud noise.”

And membership of the Kent Invicta Chamber of Commerce is also a key element of its work in the community.

“We go to lots of events and are a very active member of the Chamber’s Kent and Medway Manufacturing Focus Group (KMFG), it’s a great way to network,” explained Mike.

“Social impact is just as important as the sustainability piece for us. For the firm to thrive long after I’m no longer here, we need good relationships that shore up the next part of Syntech.

“That’s employment, skills development, relationship building. And there’s nothing more important to us than being sustainable locally in Medway and Kent and being completely engaged on our home turf.”

As for the future – Syntech Biofuel has growth on the horizon.

“The last 10 years haven’t been easy, the challenges at times have been many,” said Mike, “now we’re set to supply fuel to power some of the country’s biggest and most significant infrastructure projects.”

“Our message is simple: Syntech is ready nowa proven British solution trusted by industry to cut carbon today.” www.syntechbiofuel.com