Biotechnological Production of Biobased Polyamides

Introduction

Polyamides, commonly known as nylons, are high-performance engineering plastics used in automotive, textiles, electronics, 3D printing, and packaging. Traditionally, they are synthesized from petroleum-derived monomers like adipic acid and hexamethylenediamine, both of which have a significant environmental footprint.

The biotechnological production of biobased polyamides replaces these fossil-based monomers with microbially derived building blocks, such as cadaverine (1,5-diaminopentane), putrescine (1,4-diaminobutane), and dicarboxylic acids like sebacic acid or dodecanedioic acid. Using engineered microbes, fermentation of biomass feedstocks, and enzymatic pathways, these components can be sustainably synthesized and polymerized to create biobased nylons (e.g., PA-5,10, PA-10,10, PA-4,6), matching or exceeding the properties of their petroleum counterparts.

What Products Are Produced?

Biobased Polyamides (Nylons):

• PA-5,10 – From cadaverine and sebacic acid
• PA-10,10 – From decamethylene diamine and sebacic acid
• PA-4,6 – From putrescine and adipic acid
• PA-11 – From castor oil (11-aminoundecanoic acid)

Monomers:

• Cadaverine (1,5-DAP)
• Putrescine (1,4-DAB)
• Dicarboxylic acids (e.g., C10–C12 from fatty acid oxidation or fermentation)

Pathways and Production Methods

1. Diamine Production

• Cadaverine: From L-lysine using lysine decarboxylase (ldcC)
• Putrescine: From ornithine or arginine via ornithine decarboxylase

→ Fermentation using engineered Corynebacterium glutamicum, E. coli, or Bacillus subtilis

2. Dicarboxylic Acid Production

Sebacic acid, dodecanedioic acid, and adipic acid from:

• ω-oxidation of fatty acids in engineered yeasts (Candida, Yarrowia)
• Biotransformation of alkanes or alkenes
• Fermentation from glucose in Pseudomonas species

3. Polymerization

• Melt or solution-phase polycondensation of bio-derived diamines and diacids
• Catalysts: phosphoric acid derivatives, titanium-based catalysts
• Properties: high thermal stability, chemical resistance, tunable flexibility

Catalysts and Key Tools Used

Engineered Microorganisms:

• Corynebacterium glutamicum – Cadaverine and putrescine production
• Pseudomonas putida, E. coli – Adipic and dodecanedioic acid production
• Yarrowia lipolytica – ω-oxidation of long-chain fatty acids

Key Enzymes:

• Lysine decarboxylase (ldcC) – Lysine → cadaverine
• Monooxygenases and oxidases – For dicarboxylic acid synthesis
• Decarboxylases and aminotransferases – In amine synthesis

Fermentation Platforms:

• Fed-batch for high titers of diamines (up to 100 g/L)
• Biotransformation in aerobic stirred-tank reactors
• Green polymerization under solvent-free conditions

Case Study: DSM + Evonik – Bio-Based Polyamide 410

Highlights

• Developed EcoPaXX®: A 70% biobased nylon-410 from sebacic acid (castor oil) and cadaverine
• Properties: high melting point, low moisture uptake, automotive-grade
• Used in engine covers, brake systems, and electronics
• Fully certified under ISO 16620 for biobased content

Timeline

• 2010 – Joint development of microbial cadaverine production
• 2012 – Commercial launch of EcoPaXX
• 2016 – Automotive OEMs adopt nylon 410 for under-the-hood parts
• 2023 – Expansion into sustainable textiles and biocomposites

Global and Indian Startups Working in This Area

Global

• Genomatica (USA) – Putrescine, cadaverine, and polyamide monomer fermentation
• CJ Biomaterials (Korea) – Bio-based diamine and dicarboxylic acid production
• Evonik + DSM (EU) – Full value chain for biobased nylons
• BASF (Germany) – R&D into bio-adipic acid and biopolyamide blends

India

• Godavari Biorefineries (Maharashtra) – Castor oil derivatives for PA-11 and PA-6,10
• CSIR-NCL & CSIR-IICT – Process development for cadaverine and dicarboxylic acids
• IIT Delhi, ICT Mumbai – Pilot-scale development of bio-nylons from agro-residues
• Startups under BIRAC and BIG – Early-stage work on polyamide precursors from fermentation

Market and Demand

The global biobased polyamide market is expected to reach USD 4.8 billion by 2030, growing at a CAGR of ~9.2%, driven by demand in automotive, electronics, sustainable fashion, and high-performance packaging.

Major End-Use Segments:

• Automotive components – Engine covers, fuel lines
• Electrical and electronics – Circuit protection, connectors
• Textiles and apparel – High-performance synthetic fibers
• Industrial applications – Tubing, gear housings, chemical tanks
• 3D printing filaments – Bio-nylon blends

Key Growth Drivers

• Demand for renewable high-performance materials
• Availability of castor oil, sugar, and agro-waste feedstocks
• Regulations favoring low-carbon and BPA-free plastics
• Compatibility with existing polyamide processing methods
• Push for biobased engineering plastics in India and EU markets

Challenges to Address

• Production cost parity with petroleum-based polyamides
• Scale-up of fermentation and purification of monomers
• Moisture sensitivity of certain bio-nylons
• Limited domestic infrastructure for downstream polymerization
• Need for public–private partnerships to drive innovation

Progress Indicators

• 2009 – Cadaverine-producing E. coli strains published
• 2012 – DSM-Evonik launch first partially biobased PA
• 2018 – Biobased polyamide use expands to 3D printing and textiles
• 2022 – India begins R&D on agro-waste to diamine routes
• 2024 – Industry trials for fully biobased PA-5,10 underway in EU and Asia

Biobased polyamide production is at TRL 8–9 globally, with commercial production and product use established. In India, the process is at TRL 4–6, with pilot demonstrations and early-stage polymer R&D ongoing.

Conclusion

The biotechnological production of biobased polyamides offers a future-ready solution to reduce plastic dependency on fossil fuels while maintaining mechanical strength and thermal performance. With fermentation-derived monomers and growing industrial interest in drop-in bioplastics, bio-nylons are emerging as next-generation sustainable materials.

For India, integrating agro-based monomer production with local polymer manufacturing could unlock a new bioeconomy frontier—enabling green mobility, fashion, and electronics with materials that are both renewable and circular.

Wish to have bio-innovations industry or market research support from specialists for climate & environment? Talk to BioBiz team – Call Muthu at +91-9952910083 or send a note to ask@biobiz.in

Wish to have bio-innovations industry or market research support from specialists for climate & environment? Talk to BioBiz team – Call Muthu at +91-9952910083 or send a note to ask@biobiz.in