The future carbon challenge in aviation
- Flexible, scalable production through a globally distributed CJ1 facility producing 30,000 gallons of advanced fuel annually by early 2026 and planned to expand to 100 million gallons per site while mitigating supply chain risks and maintaining fuel quality
- High-performance sustainable fuels with CycloSAF and CycloRP provide 10 percent and 4 percent higher energy densities than conventional fuels, are fully compatible as standbys, and use abundant biomass feedstock to reduce emissions without competing with food production.
- Market readiness and strategic partnerships with completion of ASTM D4054 qualification for commercial use, 90 million gallon offtake agreements, and successful testing of aerospace and rocket propulsion applications that support net zero goals while maintaining efficiency and reliability.
The aviation industry faces increasing pressure to reduce carbon emissions while maintaining safety, performance and operational efficiency. Alternative fuels for aviation have emerged as a major solution, but many of the current options come with limitations – whether in blend ratios, energy density, or scalability of supply.
Recent advances in fuel technology have changed this narrative. New fuel formulations provide higher energy density, improved performance and compatibility with existing aircraft, enabling airlines to reduce emissions without sacrificing range or payload. These achievements also support a more flexible production and distribution network, addressing critical supply chain challenges.
As the industry moves toward net-zero emissions goals, the race is on to develop sustainable fuels that can be produced at scale, delivered reliably, and adopted seamlessly. Understanding these innovations is vital to understanding how aviation can balance growth with environmental responsibility in the coming decades.
The facility spans six acres and was intentionally designed as a scalable blueprint for future locations globally. It aims to produce 30,000 gallons of advanced fuel annually by early 2026, with engineering to support expansion to a 100-million-gallon commercial facility. “The key aspects are process integration and plant balance, which once proved to allow widely known engineering,” stressed Mukund Karanjekar, CEO and founder of CleanJoule.
This approach differs from simply expanding a single plant; Instead, CleanJoule plans to replicate the CJ1 scheme across multiple facilities around the world. “Our goal is to create a resilient, globally distributed fuel infrastructure network,” says Karanjikar. Reproducible manufacturing protocols and standard operating procedures create a solid foundation for expansion without compromising quality or efficiency.
Most importantly, this model addresses an ongoing challenge in the alternative aviation fuel industry: securing sufficient supplies to meet demand while maintaining consistent fuel quality. By enabling multiple plants in diverse geographies, CleanJoule’s strategy mitigates risks associated with supply chain disruptions and regional feedstock shortages.
Advanced fuel formulations
CleanJoule’s innovation is not just about scaling up production, it is also about redefining what sustainable aviation fuel can offer in terms of performance. The two formulations, CycloSAF and CycloRP, offer significantly different advantages over traditional SAF.
“CycloSAF has 10 percent greater power density than a typical Jet A or Jet A-1,” Karanjikar points out. “This translates into greater range, higher payload capacity, or improved fuel efficiency.” Unlike many alternative aviation fuels that are limited to 50 percent blending with conventional jet fuel, CycloSAF is designed to be a 100 percent alternative. “This means no modifications to the engine are required, which makes adoption much easier for airlines,” he adds.
Meanwhile, CycloRP targets aerospace applications, especially rocket propulsion. “It provides more than a four percent improvement in energy density compared to conventional kerosene fuel used in liquid rockets,” Karanjikar says. “It also provides ultra-cold flow properties, which is critical for space missions.”
Both fuels are produced from abundant biomass, primarily agricultural material waste, using CleanJoule’s proprietary manufacturing process. The flexibility of feedstocks and focus on waste not only reduces carbon emissions, but also addresses concerns about land use and food competition that often accompany biofuel production.
“Our process has proven successful on 11 different raw materials,” Karanjikar points out. “This flexibility allows expansion anywhere, leveraging existing agricultural supply chains without having to allocate new land.” In the United States, for example, reduced demand for ethanol will free up billions of bushels of corn, creating abundant feedstock for the production of alternative aviation fuels by 2030.
Accreditation, partnerships and readiness
Access to market scale depends not only on production, but also on regulatory certifications and partnerships. CleanJoule is nearing the end of the ASTM International D4054 qualification process, an essential step for commercial approval.
“All the tests required for a 10 percent blend of CycloSAF with Jet A have shown that it meets and even improves the performance of Jet A,” said Karanjikar. “We expect to qualify by the end of 2025, which will open the door to commercial use.” The operation of CJ1 demonstrated the readiness of the facility to produce these fuels on an industrial scale, consistent with technical and economic feasibility.
Furthermore, CleanJoule has already secured significant offtake agreements. “Our airline investors have signed on to purchase 90 million gallons of our next facility, CJ2, which will be operational soon,” reveals Karanjikar.
The collaboration extends beyond commercial aviation, with CleanJoule recently powering a rotary rocket engine (RDRE) using CycloRP in partnership with Venus Aerospace. “This test demonstrated the versatility of our fuels and demonstrated that they are capable of powering both conventional and advanced propulsion systems without compromising performance,” he explains. This opens opportunities in defense and spaceflight, expanding the impact of sustainable fuels.
Addressing industry challenges
The wider aviation industry is grappling with tightening regulations and strict net zero commitments. However, many current alternative aviation fuel options face “blend barriers” that limit their use to 50 percent blends and suffer from lower energy density compared to fossil fuels.
CleanJoule aims to overcome these limitations. “Our fuels are designed not only to be cleaner, but also to perform better,” Karanjikar emphasizes. “This allows airlines to achieve climate goals without operational trade-offs.” The company’s distributed manufacturing also supports energy independence and supply chain resilience, vital considerations amid geopolitical and market volatility.
“We view advanced fuels as one of the most practical and immediate ways to reduce emissions through aerospace – from today’s commercial flights to future space missions,” he adds. By offering quick solutions that require no engine changes, CleanJoule reduces the barriers to industry-wide adoption.
