By Andi Anderson
Innovation in household products often begins with a simple question, and the story of Aerterra shows how one idea can spark real change.
The company set out to understand why everyday furnace filters, replaced every 90 days, were still made from petroleum. This search for a better material led Aerterra to corn, a renewable and reliable resource deeply connected to American agriculture.
Aerterra co-founder and CEO Curtis Firestone said it started with a mission to find renewable, scalable, American-made materials that could perform well. After reviewing multiple options, the team found that U.S. corn met every requirement.
As Firestone explained, “We set out to find a better material… one feedstock kept meeting every criterion — U.S. corn.” This became the foundation for a new bio-based furnace filter system.
The company explored polylactic acid (PLA), a corn-based material, and confirmed that it could support MERV-rated filter performance. With support from material scientists and early testing, the company proved the idea worked.
Winning the National Corn Growers Association’s Consider Corn Challenge strengthened the concept further, showing that both the science and the agricultural community were ready for a new value-added corn product.
Aerterra filters use ultra-fine corn-based fibers that create a strong, high-performance mesh. Air passes through the filter while dust and particles are captured. The result is clean indoor air without petroleum-based materials.
The filters are PFAS-free, use no harsh chemical binders, and rely fully on U.S. corn. They are designed to reduce embodied carbon and support better airflow for efficient HVAC operation.
Corn also supports long-term performance. Corn-derived biopolymers maintain filtration quality over time, unlike some synthetic filters that depend on electrostatic charges that can weaken. The renewable nature of the material also supports a lower environmental impact.
Launching a new materials-based product came with challenges, including testing, certifications, manufacturing, and logistics. As Firestone noted, “Everything takes longer than you think… but the reward is huge.” Aerterra believes its future is promising, with plans to expand beyond furnace filters into a full line of “Corn-Based Clean Living” products. Firestone sees significant potential, saying the market is large and ready for change.
As Aerterra grows, it aims to show how renewable materials can reshape household goods while supporting farmers and protecting indoor environments.
Photo Credit: gettyimages-zoran-zeremski
Categories: Illinois, Business, Rural Lifestyle