Rigid polyurethane foam provides efficient thermal insulation, ideal for energy-saving applications in building construction. Typically derived from fossil-based polyols and diisocyanates, polyurethane is now being innovated with renewable alternatives like lignin, a byproduct of the pulp and paper industry, offering a potentially sustainable path to lower fossil dependency and enhance environmental performance. This study focuses on scaling up three lignin-based lab processes of rigid polyurethane foam synthesis to evaluate their energy consumption and industrial feasibility. The processes include: (1) direct lignin incorporation without modification, replacing 30wt.% of fossil polyols; (2) hydrolytic depolymerization of lignin, substituting 50wt.% of fossil polyols; and (3) oxypropylation of depolymerized lignin, allowing for complete replacement of fossil-based polyols.