Altalto – Waste to Sustainable Aviation Fuel

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Aviation faces one of the toughest decarbonisation challenges. Electrification isn’t practical for long-haul flights, and hydrogen remains years away from commercial readiness. That’s why sustainable aviation fuel (SAF) is attracting so much attention — and investment.

UK-based Altalto, owned by Velocys, is at the forefront. With new government funding, it is progressing plans for a plant in Immingham capable of producing around 30 million litres of SAF per year from municipal solid waste.

How it works

Altalto will use NX Circular gasification to turn waste into synthesis gas, which is then processed by Velocys’ MicroFTL technology to produce liquid fuel. Instead of landfilling or incinerating waste, the process diverts it into a fuel that can cut lifecycle emissions by up to 70% compared to kerosene.

Why it matters

The UK generates millions of tonnes of residual waste annually. Converting even a fraction into SAF reduces landfill emissions, provides domestic energy security, and helps airlines meet net-zero commitments.

The Immingham facility alone could avoid 100,000 tonnes of CO₂ equivalent emissions per year, powering the equivalent of 500 transatlantic flights.

Challenges ahead

Scaling remains the big hurdle. Global aviation consumes over 300 billion litres of fuel annually. 30 million litres is a drop in the ocean. Costs are also higher than fossil jet fuel, meaning policy support and airline commitment are essential.

Lessons for manufacturers

Altalto demonstrates how circular thinking can deliver both climate benefit and industrial opportunity. The model is replicable: turn waste streams into value, whether that’s heat, power, or fuel. Manufacturers should ask:

• What “waste” in our operations could become feedstock?

• How can partnerships turn disposal costs into revenue streams?

• Where can policy support accelerate commercialisation?

Conclusion

SAF won’t solve aviation’s challenges alone, but projects like Altalto show that circular technologies can move from concept to industrial scale. For manufacturing leaders, it’s a reminder that waste is never just waste. With the right technology and partnerships, it can become the resource that defines your next business opportunity.