Microbial Synthesis of Biobased Nylons

Introduction

Nylons (polyamides) are high-performance engineering plastics used in automotive parts, textiles, electronics, and packaging. Conventional nylon production relies on petrochemical monomers like adipic acid and hexamethylenediamine, contributing to high CO₂ emissions and nitrous oxide (N₂O) pollution.

With rising demand for sustainable materials, microbial synthesis of biobased nylons is emerging as a promising alternative. By engineering microorganisms to produce nylon monomers—such as adipic acid, cadaverine (1,5-diaminopentane), and sebacic acid—from renewable sugars or biomass, the industry is advancing toward carbon-neutral polymer manufacturing.

What Products Are Produced?

Biobased Nylon Types:

• Nylon-6,6 – From bio-adipic acid and bio-hexamethylenediamine
• Nylon-5,10 / Nylon-5,6 – From bio-cadaverine
• Nylon-6,10 – From bio-sebacic acid
• Nylon-4,6 / Nylon-12 – From short-chain or medium-chain dicarboxylic acids and diamines

Applications:

• Textiles and fibers (apparel, carpets)
• Automotive parts (engine covers, gears)
• Electronics and coatings
• Bioplastics and packaging films

Pathways and Production Methods

1. Fermentation-Based Monomer Production

a. Cadaverine (1,5-Diaminopentane)

• L-lysine → Cadaverine via lysine decarboxylase
• Engineered Corynebacterium glutamicum, E. coli

b. Adipic Acid

• Glucose → Succinic acid → 4-hydroxybutyrate → Adipic acid
• Alternative route: Muconic acid → Adipic acid

c. Sebacic Acid

• Castor oil → Sebacic acid via oxidative cleavage
• Microbial routes via engineered fatty acid metabolism under exploration

2. Enzymatic Polymerization

• Biobased monomers polymerized using lipase-based or thermal processes
• Drop-in polymerization with conventional reactors

Catalysts and Key Tools Used

Engineered Microorganisms:

• Corynebacterium glutamicum, E. coli, Bacillus subtilis – Cadaverine & lysine producers
• Pseudomonas putida, Saccharomyces cerevisiae – Aromatic monomer platforms
• Yarrowia lipolytica – Fatty acid-derived dicarboxylic acids

Key Enzymes:

• Lysine decarboxylase (LDC) – Cadaverine synthesis
• 4-hydroxybutyrate dehydrogenase – Adipic acid intermediates
• Monooxygenases, oxidases – For fatty acid chain oxidation

Fermentation Tools:

• Two-stage fermentation for monomer accumulation
• Fed-batch or continuous systems for scale-up
• Downstream separation: Ion exchange, crystallization

Case Study: DSM & Evonik – Biobased Nylon-5,10 from Cadaverine

Highlights

• Corynebacterium glutamicum engineered to produce cadaverine from sugar
• Cadaverine polymerized with bio-sebacic acid to form Nylon-5,10
• Used in automotive components and textile applications
• Improved thermal and mechanical properties over fossil-based nylon-6

Timeline

• 2011 – Microbial cadaverine production announced
• 2014 – Nylon-5,10 commercialized for automotive parts
• 2017 – Expanded into textile and electronics markets
• 2022 – Life Cycle Assessment (LCA) confirmed lower carbon footprint

Global and Indian Startups Working in This Area

Global

• Genomatica (USA) – Bio-adipic acid via synthetic microbes
• Evonik (Germany) – Nylon-5,10 from bio-cadaverine
• DSM (Netherlands) – Partnered in nylon monomer development
• Arkema (France) – Castor oil-based sebacic acid for nylon-6,10

India

• Godavari Biorefineries – Working on bio-polyamide platforms
• CSIR-NIIST and NCL Pune – Cadaverine and muconic acid from agri-sugars
• ICT Mumbai – Developing microbial adipic acid synthesis
• BIRAC-funded incubatees – Exploring enzyme polymerization of bio-nylons

Market and Demand

The global nylon market was valued at USD 32 billion in 2023, expected to reach USD 45 billion by 2030, with biobased nylons projected to grow at ~13% CAGR, fueled by automotive light-weighting, green textiles, and recyclable packaging.

Major End-Use Segments:

• Engineering plastics – Automotive, electronics
• Fibers and apparel – Sportswear, carpets
• Bioplastics and sustainable packaging

Key Growth Drivers

• Demand for low-carbon performance polymers
• Abundant renewable feedstocks for monomer production
• Consumer push for green fibers and recyclable materials
• Strong industry partnerships and polymer compatibility
• Emerging circular nylon initiatives (bio-based and recyclable)

Challenges to Address

• Monomer toxicity to microbes during fermentation
• Balancing yield vs. productivity in engineered strains
• High purification costs for food/pharma-grade nylons
• Scale-up of enzymatic polymerization still under development
• India-specific: Limited industrial uptake of bio-based nylons

Progress Indicators

• 2011 – Bio-cadaverine pathway commercialized
• 2014–2016 – Pilot-scale production of bio-adipic acid in USA/EU
• 2018 – India explores sugar-to-cadaverine fermentation
• 2021 – First bio-nylon trial from castor + cadaverine blend
• 2024 – Bio-nylon integration with PBT and PU industries in progress

Globally, microbial synthesis of biobased nylon monomers is at TRL 8–9, with commercialization in progress. In India, it is at TRL 5–6, moving from lab-scale to pilot demonstration.

Conclusion

Microbial synthesis of biobased nylons marks a critical shift from fossil-based polymer production toward sustainable, renewable, and biodegradable alternatives. With successful engineering of microbes for monomer synthesis and scalable polymerization strategies, industries are unlocking new value chains in bio-textiles, green mobility, and circular materials.

As India advances its sugar and castor-based chemical economy, microbial bio-nylons present a high-impact opportunity for innovation, exports, and environmental leadership.

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