How PBS is Produced from Bio-Based Succinic Acid and BDO
Core Steps in the Production Pathway:
- Feedstock Preparation
- Bio-succinic acid is derived from fermentation of sugars or biomass using engineered bacteria (e.g., Actinobacillus succinogenes, Basfia succiniciproducens).
- Bio-BDO is produced from sugars or succinic acid via fermentation or catalytic hydrogenation.
- Esterification and Polycondensation
- Succinic acid reacts with 1,4-butanediol to form oligomers via esterification at 150–180°C.
- Oligomers undergo polycondensation under vacuum at higher temperatures (~220°C) to form high-molecular-weight PBS.
- Pelletization and Application
- The final polymer is pelletized and used in film extrusion, thermoforming, injection molding, and blown film applications.
Case Study: PTTMCC Biochem – Thailand’s Fully Bio-Based PBS
Highlights:
- Joint venture between PTT Global Chemical (Thailand) and Mitsubishi Chemical (Japan).
- World’s first commercial PBS plant using bio-based succinic acid and bio-BDO.
- Product brands: BioPBS™ FZ (compostable packaging), BioPBS™ FS (injection molding).
Timeline & Outcome:
- 2011: Joint venture established; R&D on bio-based PBS formulation.
- 2015: 20,000 TPA commercial PBS plant inaugurated in Rayong, Thailand.
- 2017–2020: BioPBS™ used in shopping bags, straws, and agricultural films.
- 2022: Expanded into flexible packaging and paper coating applications.
- 2023–2024: Signed distribution deals in EU and India; pursuing certified compostable applications.
Global Startups and Innovators
- Succinity (Germany) – BASF–Corbion JV; produces bio-succinic acid used for PBS production.
- CJ Biomaterials (Korea) – Formerly CJ CheilJedang; developing PBS blends with improved properties.
- Reverdia (Netherlands) – DSM-Total JV (now inactive) previously supplied bio-succinic acid for PBS.
- NaturePlast (France) – Offers PBS compounds blended with natural fibers.
- Tianan Biologic (China) – Supplies PBS for global packaging and mulch film markets.
India’s Position
- India has demonstrated capabilities in producing succinic acid via fermentation at pilot scales (e.g., NCL Pune, ICT Mumbai).
- No domestic commercial PBS production yet, but interest from bioplastic converters and FMCG brands is growing.
- Companies like Saraswati Plastotech and EnviGreen have explored PBS as a compostable film alternative.
- India’s push for EPR and compostable packaging offers a growing downstream market for PBS applications.
Commercialization Outlook
Market & Demand
- Global PBS market: ~$650 million (2024); CAGR: ~8–10%.
- Key applications:
- Compostable bags & films
- Food packaging & cutlery
- Agricultural mulch
- 3D printing & medical applications
Key Drivers
- Ban on single-use plastics in multiple countries.
- Growing demand for certified compostable alternatives.
- Potential for fully bio-based, cradle-to-cradle polymer systems.
- Technological maturity in fermentation-based succinic acid and BDO.
Challenges to Address
- Bio-based BDO and succinic acid still costlier than fossil equivalents.
- PBS has limited barrier properties, restricting food packaging use without coating.
- Scale-up challenges in India due to limited PBS polymerization infrastructure.
- Need for composting infrastructure and certification bodies to boost market uptake.
Progress Indicators
- 2010–2013: Bio-succinic acid commercialized by Reverdia, BioAmber, and Succinity.
- 2015: PTTMCC Biochem launches full-scale PBS plant in Thailand.
- 2017–2021: PBS enters consumer goods, foodservice, and agriculture sectors.
- 2022–2024: India begins regulatory approval of compostable PBS bags; startups test PBS blends.
- India (2024): Multiple DST and DBT-funded studies on PBS copolymers and fillers for packaging use.
Globally, PBS from bio-succinic acid and bio-BDO is at TRL 9, with commercial-scale production and global distribution. In India, the TRL is 5–6, with active R&D and pre-commercial prototyping but no current polymer production facilities.
Conclusion
Polybutylene succinate is one of the most technically mature and industrially scalable biodegradable polyesters. With successful case studies like PTTMCC Biochem and strong traction in Europe and Southeast Asia, PBS has proven itself across packaging, agriculture, and disposable goods. India’s cast-off glycerol, sugarcane, and agro-waste streams offer fertile ground for local succinic acid and BDO production. Realizing domestic PBS production will require strategic investment in polyester polymerization units, market push from policy (e.g., compostable packaging mandates), and collaboration between bio-refiners, converters, and brands.
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