Via Separations Deploys First-of-a-Kind Project with International Paper
All photos were taken by Jillian Wilson.
Scaling Solutions for Decarbonizing Industrial Manufacturing
Industries like cement, steel, and paper production generate 30% of U.S. emissions, yet outdated processes and limited incentives often stall progress. Prime Impact Fund portfolio company, Via Separations, is rewriting the rules of industrial energy efficiency. With groundbreaking technology, Via Separations is breaking down barriers and unlocking a cleaner future for manufacturing.
The Journey to a 100x Scale-Up
In 2024, Via Separations launched its first-of-a-kind (FOAK) commercial project, Project Kodiak, at International Paper’s mill in Alberta, Canada. This project was a 100x scale-up of their groundbreaking technology, which replaces traditional energy-intensive evaporators with energy-efficient separation membranes. The decision to scale up by 100x, rather than taking smaller steps, was pivotal. Shreya Dave, Via Separation’s CEO, shared the story with Trellis Climate’s Managing Director, Lara Pierpoint, on The Green Blueprint podcast. In this episode, Shreya explained how this decision to scale up 100x factored in many considerations, including the fact that the project’s fixed costs and lead times would have been nearly identical regardless of whether they scaled up 10x or 100x.
Via Separations chose not to deplete its Series B capital reserves on Project Kodiak alone. Shreya described the challenging search for FOAK-specific funding, noting that much of the available capital was for early-of-a-kind projects. As a result, Via Separations turned to a complex blend of financing that included equipment loans, venture debt, equity, and a grant. This financial ingenuity underscores the critical need for innovative capital structures tailored to FOAK projects—an area where philanthropists can play a transformative role.
A Bold Approach to Execution
Via Separations decided to be their own general contractor for the project. This allowed them to stay close to the details, speed up lead times, and document their learnings while navigating the unique challenges of scaling up a first-of-a-kind solution. The result was a system capable of processing ~20% of International Paper’s black liquor—a byproduct of the paper manufacturing process—while cutting energy consumption by 76% compared to traditional methods.
The Impact of Innovation
Project Kodiak is just the beginning. The lessons learned from it laid the foundation for future projects. Via Separations is now designing and delivering systems with larger capacity and reduced costs. As Shreya Dave noted, “We are taking the data from this first-of-a-kind project…building a couple more projects that have larger capacity but are lower in cost and footprint…and you’ll see us at your neighborhood pulp mill in the future.”
Via Separation’s innovation demonstrates the immense potential for process intensification to reduce emissions, energy, and costs, paving the way for a sustainable industrial future. For a deeper dive into the decarbonization and financial impact of Via’s technology, explore the Whitepaper, Transforming Industrial Manufacturing: Via Separations Delivers Energy-Efficient Process Intensification, and watch the video to learn more about their journey.
Prime’s Role in Advancing FOAK Climate Solutions
At Prime Coalition, we recognize that scaling FOAK projects like Project Kodiak requires more than technical expertise—it demands a customized approach to financing. Through Trellis Climate, Prime’s newest catalytic investment program, we aim to address the critical funding gap for FOAK projects through catalytic capital. Trellis provides philanthropists with a pathway to invest in transformative climate solutions.
Via Separations’ story is an example of what’s possible when companies have the capital they need to deploy FOAK projects. But there’s more work to do. An estimated $40 billion is needed to bridge the capital gap for FOAK climate solutions, which remain essential stepping stones for decarbonizing industrial sectors. Each project requires a tailored capital stack to overcome barriers and scale its impact.
To work with us in scaling climate solutions, contact Lara Pierpoint, Managing Director of Trellis Climate, at lara@primecoalition.org. Together, we will unlock catalytic capital and change the future of climate finance.
