Algal bioplastics: current market trends and technical aspects

Value-added utilization technologies for seaweed processing waste in a circular economy: Developing a sustainable modern seaweed industry

The global seaweed industry annually consumes approximately 600,000 tons of dried algal biomass to produce algal hydrocolloids, yet only 15-30% of this biomass is utilized, with the remaining 70-85% discarded or released as scum or wastewater during the hydrocolloid extraction process. This residual biomass is often treated as waste and not considered for further commercial use, which contradicts the principles of sustainable development. In reality, the residual algal biomass could be employed to extract additional biochemical components, such as pigments, proteins, and cellulose, and these ingredients have important application prospects in the food sector. According to the biorefinery concept, recycling various products alongside the principal product enhances overall biomass utilization. Transitioning from traditional single-product processes to multi-product biorefineries, however, raises operating costs, presenting a significant challenge. Alternatively, developing value-added utilization technologies that target seaweed waste without altering existing processes is gaining traction among industry practitioners. Current advancements include methods such as separation and extraction of residual biomass, anaerobic digestion, thermochemical conversion, enzymatic treatment, functionalized modification of algal scum, and efficient utilization through metabolic engineering. These technologies hold promise for converting seaweed waste into alternative proteins, dietary supplements, and bioplastics for food packaging. Combining multiple technologies may offer the most effective strategy for future seaweed waste treatment. Nonetheless, most research on value-added waste utilization remains at the laboratory scale, necessitating further investigation at pilot and commercial scales.

Drying strategies for maximizing polyhydroxybutyrate recovery from microalgae cultivated in a raceway pond: A comparative study

Polyhydroxybutyrate (PHB) derived from microalgae are considered a promising alternative bioplastic material to replace synthetic plastics. This study evaluated the effects of various drying techniques (sun, freeze, oven and air drying) on PHB recovery from microalgae. Freeze drying recovered the maximum PHBs (6.2%) followed by sun drying (5.2%), air drying (2.3%), oven drying (2%), and the lowest in wet biomass (1.2%). The most energy-intensive drying method was freeze drying (26.83 kW) followed by oven drying (3 kW) while the other methods did not require energy. The minimum time requirement for drying was oven drying (6 h), followed by freeze drying (24 h), sun drying (48-72 h), and air drying (96-120 h) while wet biomass did not require time. In terms of PHB yield per unit time, oven (0.33%/h) is a more effective drying technique than freeze drying (0.25%/h) which produces 24.24% higher PHB yield per unit time. Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) confirmed PHB structure and thermal stability up to 300 °C from dried biomasses compared to wet biomass at 200 °C. This study indicated that drying techniques significantly influence the PHB recovery from microalgae biomass. Findings also revealed that the oven dried technique can be efficiently scaled up for PHB recovery.

Isolation and characterization of a Halomonas species for non-axenic growth-associated production of bio-polyesters from sustainable feedstocks

Biodegradable plastics are urgently needed to replace petroleum-derived polymeric materials and prevent their accumulation in the environment. To this end, we isolated and characterized a halophilic and alkaliphilic bacterium from the Great Salt Lake in Utah. The isolate was identified as a Halomonas species and designated "CUBES01." Full-genome sequencing and genomic reconstruction revealed the unique genetic traits and metabolic capabilities of the strain, including the common polyhydroxyalkanoate (PHA) biosynthesis pathway. Fluorescence staining identified intracellular polyester granules that accumulated predominantly during the strain's exponential growth, a feature rarely found among natural PHA producers. CUBES01 was found to metabolize a range of renewable carbon feedstocks, including glucosamine and acetyl-glucosamine, as well as sucrose, glucose, fructose, and further glycerol, propionate, and acetate. Depending on the substrate, the strain accumulated up to ~60% of its biomass (dry wt/wt) in poly(3-hydroxybutyrate), while reaching a doubling time of 1.7 h at 30°C and an optimum osmolarity of 1 M sodium chloride and a pH of 8.8. The physiological preferences of the strain may not only enable long-term aseptic cultivation but also facilitate the release of intracellular products through osmolysis. The development of a minimal medium also allowed the estimation of maximum polyhydroxybutyrate production rates, which were projected to exceed 5 g/h. Finally, also, the genetic tractability of the strain was assessed in conjugation experiments: two orthogonal plasmid vectors were stable in the heterologous host, thereby opening the possibility of genetic engineering through the introduction of foreign genes.

IMPORTANCE

The urgent need for renewable replacements for synthetic materials may be addressed through microbial biotechnology. To simplify the large-scale implementation of such bio-processes, robust cell factories that can utilize sustainable and widely available feedstocks are pivotal. To this end, non-axenic growth-associated production could reduce operational costs and enhance biomass productivity, thereby improving commercial competitiveness. Another major cost factor is downstream processing, especially in the case of intracellular products, such as bio-polyesters. Simplified cell-lysis strategies could also further improve economic viability.

Tuning the Structure-Property Relationships in Binary and Ternary Blends of PLA/PBAT/PHBH

While the brittle polylactide (PLA) has a high durability among bioplastics, poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBH) with certain ductility exhibits facile compostability. The addition of polybutylene adipate terephthalate (PBAT) may also be used to improve the ductility and toughness of brittle bioplastics. Binary and ternary blends of PLA/PBAT/PHBH based on either PLA or PHBH as the matrix have been manufactured using a twin-screw extruder. The melt rheological, mechanical, and morphological properties of the processed samples were examined. Binary blends of PLA/PHBH show superior strength, with the PLA75/PHBH25 blend exhibiting a tensile strength of 35.2 ± 3.0 MPa, which may be attributed to miscible-like morphology. In contrast, blends of PLA with PBAT demonstrate low strength, with the PLA50/PBAT50 blend exhibits a tensile strength of 9.5 ± 2.0 MPa due to the presence of large droplets in the matrix. PBAT-containing blends exhibit lower impact strengths compared to PHBH-containing blends. For instance, a PLA75/PBAT25 blend displays an impact strength of 1.76 ± 0.1 kJ/m2, whereas the PHBH75/PBAT25 blend displays an impact strength of 2.61 ± 0.3 kJ/m2, which may be attributed to uniformly dispersed PBAT droplets.

Seaweed as Basis of Eco-Sustainable Plastic Materials: Focus on Alginate

Seaweed, a diverse and abundant marine resource, holds promise as a renewable feedstock for bioplastics due to its polysaccharide-rich composition. This review explores different methods for extracting and processing seaweed polysaccharides, focusing on the production of alginate plastic materials. Seaweed emerges as a promising solution, due to its abundance, minimal environmental impact, and diverse industrial applications, such as feed and food, plant and soil nutrition, nutraceutical hydrocolloids, personal care, and bioplastics. Various manufacturing techniques, such as solvent casting, injection moulding, and extrusion, are discussed for producing seaweed-based bioplastics. Alginate, obtained mainly from brown seaweed, is particularly known for its gel-forming properties and presents versatile applications in many sectors (food, pharmaceutical, agriculture). This review further examines the current state of the bioplastics market, highlighting the growing demand for sustainable alternatives to conventional plastics. The integration of seaweed-derived bioplastics into mainstream markets presents opportunities for reducing plastic pollution and promoting sustainability in material production.

Algal-based bioplastics: global trends in applied research, technologies, and commercialization

The excessive global demand for plastic materials has resulted in severe plastic waste pollution. Conventional plastics derived from non-renewable fossil fuels are non-biodegradable, leading to significant environmental problems. Algal-based bioplastics represent a more viable, renewable, and sustainable alternative to conventional plastics. They have identical properties and characteristics as conventional plastics while being naturally biodegradable. The potential of the algal biomass value chain has already been well-established by researchers. Here, we review the novel insights on research, technology, and commercialization trends of algal-based bioplastics, encompassing macroalgae and green microalgae/cyanobacteria. Data showed that within the last decade, there has been substantial interest in utilizing microalgae for biopolymer production, with more focus on using cyanobacterial species compared to green algae. Moreover, most of the research conducted has largely focused on the production of PHA or its co-polymers. Since 2011, there have been a total of 55 patents published related to algal-based bioplastics production. To date, ~ 81 entities worldwide (commercial and private businesses) produce bioplastics from algae. Overall results of this study emphasized that even with the economic and social challenges, algae possess a substantial potential for the sustainable development of bioplastics while also addressing the UN's SDGs.

Green Synthesis of Bioplastics from Microalgae: A State-of-the-Art Review

The synthesis of conventional plastics has increased tremendously in the last decades due to rapid industrialization, population growth, and advancement in the use of modern technologies. However, overuse of these fossil fuel-based plastics has resulted in serious environmental and health hazards by causing pollution, global warming, etc. Therefore, the use of microalgae as a feedstock is a promising, green, and sustainable approach for the production of biobased plastics. Various biopolymers, such as polyhydroxybutyrate, polyurethane, polylactic acid, cellulose-based polymers, starch-based polymers, and protein-based polymers, can be produced from different strains of microalgae under varying culture conditions. Different techniques, including genetic engineering, metabolic engineering, the use of photobioreactors, response surface methodology, and artificial intelligence, are used to alter and improve microalgae stocks for the commercial synthesis of bioplastics at lower costs. In comparison to conventional plastics, these biobased plastics are biodegradable, biocompatible, recyclable, non-toxic, eco-friendly, and sustainable, with robust mechanical and thermoplastic properties. In addition, the bioplastics are suitable for a plethora of applications in the agriculture, construction, healthcare, electrical and electronics, and packaging industries. Thus, this review focuses on techniques for the production of biopolymers and bioplastics from microalgae. In addition, it discusses innovative and efficient strategies for large-scale bioplastic production while also providing insights into the life cycle assessment, end-of-life, and applications of bioplastics. Furthermore, some challenges affecting industrial scale bioplastics production and recommendations for future research are provided.

An investigation of the environmental implications of bioplastics: Recent advancements on the development of environmentally friendly bioplastics solutions

The production and utilization of plastics may prove beneficial, but the environmental impact suggests the opposite. The single-use plastics (SUP) and conventional plastics are harmful to the environment and need prompt disposal. Bioplastics are increasingly being considered as a viable alternative to conventional plastics due to their potential to alleviate environmental concerns such as greenhouse gas emissions and pollution. However, the previous reviews revealed a lack of consistency in the methodologies used in the Life Cycle Assessments (LCAs), making it difficult to compare the results across studies. The current study provides a systematic review of LCAs that assess the environmental impact of bioplastics. The different mechanical characteristics of bio plastics, like tensile strength, Young's modulus, flexural modulus, and elongation at break are reviewed which suggest that bio plastics are comparatively much better than synthetic plastics. Bioplastics have more efficient mechanical properties compared to synthetic plastics which signifies that bioplastics are more sustainable and reliable than synthetic plastics. The key challenges in bioplastic adoption and production include competition with food production for feedstock, high production costs, uncertainty in end-of-life management, limited biodegradability, lack of standardization, and technical performance limitations. Addressing these challenges requires collaboration among stakeholders to drive innovation, reduce costs, improve end-of-life management, and promote awareness and education. Overall, the study suggests that while bioplastics have the potential to reduce environmental impact, further research is needed to better understand their life cycle and optimize their end-of-life (EoL) management and production to maximize their environmental benefits.

Feasibility of bioplastic production using micro- and macroalgae- A review

Plastic disposal and their degraded products in the environment are global concern due to its adverse effects and persistence in nature. To overcome plastic pollution and its impacts on environment, a sustainable bioplastic production using renewable feedstock's, such as algae, are envisioned. In this review, the production of polymer precursors such as polylactic acid, polyhydroxybutyrates, polyhydroxyalkanoates, agar, carrageenan and alginate from microalgae and macroalgae through direct conversion and fermentation routes are summarized and discussed. The direct conversion of algal biopolymers without any bioprocess (whole algal biomass used emphasizing zero waste discharge concept) favours economic feasibility. Whereas indirect method uses conversion of algal polymers to monomers after pretreatment followed by bioplastic precursor production by fermentation are emphasized. This review paper also outlines the current state of technological developments in the field of algae-based bioplastic, both in industry and in research, and highlights the creation of novel solutions for green bioplastic production employing algal polymers. Finally, the cost economics of the bioplastic production using algal biopolymers are clearly mentioned with future directions of next level bioplastic production. In this review study, the cost estimation was given at laboratory level bioplastic production using casting methods. Further development of bioplastics at pilot scale level may give clear economic feasibility of production at industry. Here, in this review, we emphasized the overview of algal biopolymers for different bioplastic product development and its economic value and also current industries involved in bioplastic production.

Save the planet with green industries using algae

We can use photosynthesis to capture carbon and make industries greener. Algae-driven carbon capture and manufacturing offer the potential for reducing CO2 emissions while also producing commodities such as bioplastics.

Biodegradable hybrid biopolymer film based on carboxy methyl cellulose and selenium nanoparticles with antifungal properties to enhance grapes shelf life

In the current study, cellulose was extracted from sugarcane bagasse and further converted into carboxy methyl cellulose. The morphological, chemical, and structural characterization of synthesizeed carboxy methyl cellulose was performed. Further, the biopolymer was fabricated with mycogenic selenium nanoparticles and used to develop the biopolymer films. The developed biopolymer films were examined for the fruit shelf life stability, antifungal activity, and biodegradation potential. The results revealed that grapes wrapped with biofilms showed enhanced shelf life of fruit at all storage time intervals. The study also witnesses the antifungal activity of biopolymer films with a remarkable inhibitory action on the spores of Fusarium oxysporum and Sclerospora graminicola phytopathogens. Lastly, the biopolymer films were significantly degradable in the soil within two weeks of incubation. Thus, the developed biopolymer films exhibit multifaceted properties that can be used as an alternative to synthetic plastics for fruit packaging and also helps in protecting against fungal contaminants during storage with naturally degradable potential.