Biotechnological Production of Biobased Polyesters

Introduction

Polyesters are a major class of polymers used in packaging, textiles, automotive parts, coatings, and biodegradable plastics. Traditionally derived from petroleum-based monomers such as terephthalic acid and ethylene glycol, conventional polyester production contributes heavily to carbon emissions and plastic pollution.

Biotechnological production of biobased polyesters harnesses renewable feedstocks, engineered microorganisms, and green chemistry to synthesize polyesters with low environmental impact. From polylactic acid (PLA) and polyhydroxyalkanoates (PHA) to biobased PET and polybutylene succinate (PBS), this approach enables the creation of materials with comparable or superior properties to their fossil-based counterparts.

What Products Are Produced?

• Polylactic Acid (PLA) – Packaging films, disposable cutlery, medical implants
• Polyhydroxyalkanoates (PHA) – Biodegradable plastics for agriculture, cosmetics
• Biobased PET – Bottles, textiles, fibers
• Polybutylene Succinate (PBS) – Compostable bags, mulch films
• Polyethylene Furanoate (PEF) – Bottle-grade barrier plastic (bio-replacement for PET)

Pathways and Production Methods

1. Fermentative Monomer Production

• Lactic acid from glucose/sugar → Polymerized into PLA
• 3-Hydroxybutyrate, 3-hydroxyvalerate by Cupriavidus necator, Halomonas spp. → PHA
• Succinic acid, 1,4-butanediol, and ethylene glycol from sugar/starch → PBS/PET

2. Enzymatic and Microbial Polymerization

• Some polyesters like PHA are directly produced intracellularly by microbes
• Others require monomer purification and polymerization through heat or enzymes

3. Hybrid Approaches

• Microbial fermentation + Chemical polymerization
• Example: Bio-based ethylene glycol from ethanol + Terephthalic acid → Bio-PET

Catalysts and Key Tools Used

Microorganisms

• Cupriavidus necator, Halomonas, Pseudomonas putida – PHA production
• Lactobacillus spp., Bacillus coagulans – Lactic acid producers
• Saccharomyces cerevisiae, Corynebacterium glutamicum – Succinic acid/BDO platforms

Enzymes & Metabolic Tools

• PHA synthases, L-lactate dehydrogenase, succinate dehydrogenase
• CRISPR-Cas9 and synthetic promoters for optimized pathways
• Modular pathway engineering for custom polymer chain length & flexibility

Process Innovations

• Fed-batch fermentation for high cell density
• Cell recycling, ISPR for continuous PHA recovery
• Thermal and enzymatic polymerization units for monomer-to-polymer conversion

Case Study: NatureWorks – PLA Production at Commercial Scale

Highlights

• Produces Ingeo™ PLA from corn-based lactic acid
• World’s largest PLA biopolymer facility in Nebraska
• Supplies global packaging and textiles market
• 100% biobased, industrially compostable under ASTM D6400

Timeline

• 2002 – First commercial PLA production begins
• 2010 – Expanded into textiles and durable goods
• 2021 – Announced second plant in Thailand (sugarcane-based feedstock)
• 2024 – Ingeo used in food service, 3D printing, electronics

Global and Indian Startups Working in This Area

Global

• NatureWorks (USA) – PLA from corn
• Danimer Scientific (USA) – PHA bioplastics
• Avantium (Netherlands) – PEF from furandicarboxylic acid
• Total Corbion (Netherlands) – PLA blends and resins

India

• Lucro Plastecycle, Envigreen – PLA and starch blends
• Sea6 Energy – Algae-based PHA and biopolyesters
• Godavari Biorefineries – Succinic acid for PBS
• IIT Delhi, CSIR-NIIST – Enzyme and strain development for PHA
• BIRAC startups – Focused on packaging and agriculture film applications

Market and Demand

The global biobased polyester market reached USD 10.4 billion in 2023, projected to reach USD 21.6 billion by 2030 at a CAGR of ~10.5%. Demand is driven by regulatory bans on single-use plastics, corporate sustainability mandates, and consumer awareness.

Major End-Use Segments:

• Food packaging and disposables
• Agriculture films and mulch
• Textile fibers and apparel
• Medical implants and drug delivery devices

Key Growth Drivers

• Regulations phasing out non-biodegradable plastics
• Retail and FMCG brands committing to circular materials
• Abundant feedstocks like sugarcane, corn, seaweed
• Industrial composting infrastructure improvements
• Drop-in capability of bio-PET in existing PET infrastructure

Challenges to Address

• Production cost parity with petro-based plastics
• Mechanical strength limitations in some bio-polyesters
• End-of-life handling (composting vs. recycling)
• Feedstock competition with food crops
• India-specific: Lack of scale-up facilities and price-sensitive market

Progress Indicators

• 2005–2010 – PLA and PHA reach pilot scale
• 2013 – Bio-PET enters commercial beverage packaging
• 2018 – India begins PHA trials using sugarcane and seaweed
• 2023–2024 – Bio-polyester films used in retail chains and food delivery

Biobased polyester production is at TRL 9 globally, with several technologies commercialized; in India, TRL 6–8, with rapid progress in PHA and PLA scaling.

Conclusion

Biotechnological production of biobased polyesters presents a powerful pathway to solving the dual crisis of plastic pollution and fossil fuel dependency. With diverse feedstocks, scalable processes, and proven applications, these materials are transforming packaging, textiles, and medical sectors.

India stands to benefit greatly by integrating bio-polyester innovation into its agriculture and manufacturing ecosystems, creating new green jobs and driving sustainable material transitions on both local and global scales.

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