Sustainable Process for the Production of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) from Renewable Resources: A Simulation Study

Techno-economic assessment of biopolymer production from methane and volatile fatty acids: effect of the reactor size and biomass concentration on the poly(3-hydroxybutyrate-co-3-hydroxyvalerate) selling price

Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) is a biobased and biodegradable polymer that could efficiently replace fossil-based plastics. However, its widespread deployment is slowed down by the high production cost. In this work, the techno-economic assessment of the process for producing poly(3-hydroxybutyrate-co-3-hydroxyvalerate) from low-cost substrates, such as methane and valeric acid derived from the anaerobic digestion of organic wastes, is proposed. Several strategies for cost abatement, such as the use of a mixed consortium and a line for reagent recycling during downstream, were adopted. Different scenarios in terms of production, from 100 to 100,000 t/y, were analysed, and, for each case, the effect of the reactor volume (small, medium and large size) on the selling price was assessed. In addition, the effect of biomass concentration was also considered. Results show that the selling price of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) is minimum for a production plant with 100,000 t/y capacity, accounting for 18.4 €/kg, and highly influenced by the biomass concentration since it can be reduced up to 8.6 €/kg by increasing the total suspended solids from 5 to 30 g/L, This adjustment aligns the breakeven point of PHBV with the reported average commercial price.

Production of poly(3-hydroxybutyrate) and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) from methane and volatile fatty acids: properties, metabolic routes and current trend

Polyhydroxyalkanoates (PHAs) are biobased and biodegradable polymers that could effectively replace fossil-based and non-biodegradable plastics. However, their production is currently limited by the high production costs, mainly due to the costly carbon sources used, low productivity and quality of the materials produced. A potential solution lies in utilizing cheap and renewable carbon sources as the primary feedstock during the biological production of PHAs, paving the way for a completely sustainable and economically viable process. In this review, the opportunities and challenges related to the production of polyhydroxyalkanoates using methane and volatile fatty acids (VFAs) as substrates were explored, with a focus on poly(3-hydroxybutyrate) and poly(3-hydroxybutyrate-co-3-hydroxyvalerate). The discussion reports the current knowledge about promising Type II methanotrophs, the impact of process parameters such as limiting nutrients, CH4:O2 ratio and temperature, the type of co-substrate and its concentration. Additionally, the strategies developed until now to enhance PHA production yields were also discussed.

The green revolution of food waste upcycling to produce polyhydroxyalkanoates

This review emphasizes the urgent need for food waste upcycling as a response to the mounting global food waste crisis. Focusing on polyhydroxyalkanoates (PHAs) as an alternative to traditional plastics, it examines the potential of various food wastes as feedstock for microbial fermentation and PHA production. The upcycling of food waste including cheese whey, waste cooking oil, coffee waste, and animal fat is an innovative practice for food waste management. This approach not only mitigates environmental impacts but also contributes to sustainable development and economic growth. Downstream processing techniques for PHAs are discussed, highlighting their role in obtaining high-quality materials. The study also addresses sustainability considerations, emphasizing biodegradability and recycling, while acknowledging the challenges associated with this path.

Valorization of Cabbage Waste as a Feedstock for Microbial Polyhydroxyalkanoate Production: Optimizing Hydrolysis Conditions and Polyhydroxyalkanoate Production

Establishing a platform for the bioconversion of waste resources into value-added compounds is critical for achieving a sustainable and eco-friendly economy. Herein, we produced polyhydroxyalkanoate via microbial fermentation using cabbage waste as a feedstock and metabolically engineered Escherichia coli. For this, the hydrolysis conditions of cabbage waste were optimized by focusing on parameters such as substrate and enzyme concentrations to enhance the saccharification efficiency. The phaABC operon, which encodes key enzymes responsible for polyhydroxyalkanoate biosynthesis in Ralstonia eutropha H16, was overexpressed in E. coli. Using cabbage hydrolysate as the feedstock, this engineered E. coli strain could produce poly(3-hydroxybutyrate) with a polymer content of 26.0 wt % of dry cell weight. Moreover, malic acid in cabbage hydrolysate significantly enhanced poly(3-hydroxybutyrate) production; the addition of 0.5 g/L malic acid markedly increased poly(3-hydroxybutyrate) content by 59.9%. This study demonstrates the potential of cabbage waste as a promising raw material for the microbial production of polyhydroxyalkanoate.

Exploring New Strategies for Optimizing the Production of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) from Methane and VFAs in Synthetic Cocultures and Mixed Methanotrophic Consortia

In this work, the potential of a synthetic coculture and a mixed methanotrophic consortium to synthesize poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) from renewable and waste-based feedstocks was assessed batchwise. Methylocystis parvuscocultivated with Rhodococcus opacus and a Methylocystis-enriched culture previously grown on methane were subjected to nutrient starvation in a medium enriched with valeric acid (30% w w-1 of Ctot) or with a VFAs mixture containing acetic, propionic, butyric, and valeric acids (15% w w-1 of Ctot) under a CH4:O2 or air atmosphere. For all test series, pH was adjusted to 7 after adding the cosubstrates, and a negligible substrate consumption or polymer production was considered the end point of the trial. Results showed that valeric acid promoted PHBV accumulation in both cultures regardless of the atmosphere. Interestingly, the mixture of VFAs supported PHBV accumulation only in the presence of methane. The highest PHBV contents for the coculture and the mixed consortium, equal to 73.7 ± 2.5% w w-1 and 49.6 ± 13% w w-1, respectively, were obtained with methane and the VFAs mixture. This study demonstrates the suitability of cocultures and biobased cosubstrates for the sustainable production of the biodegradable polymer PHBV.

Valorization of organic wastes using bioreactors for polyhydroxyalkanoate production: Recent advancement, sustainable approaches, challenges, and future perspectives

Microbial polyhydroxyalkanoates (PHA) are encouraging biodegradable polymers, which may ease the environmental problems caused by petroleum-derived plastics. However, there is a growing waste removal problem and the high price of pure feedstocks for PHA biosynthesis. This has directed to the forthcoming requirement to upgrade waste streams from various industries as feedstocks for PHA production. This review covers the state-of-the-art progress in utilizing low-cost carbon substrates, effective upstream and downstream processes, and waste stream recycling to sustain entire process circularity. This review also enlightens the use of various batch, fed-batch, continuous, and semi-continuous bioreactor systems with flexible results to enhance the productivity and simultaneously cost reduction. The life-cycle and techno-economic analyses, advanced tools and strategies for microbial PHA biosynthesis, and numerous factors affecting PHA commercialization were also covered. The review includes the ongoing and upcoming strategies viz. metabolic engineering, synthetic biology, morphology engineering, and automation to expand PHA diversity, diminish production costs, and improve PHA production with an objective of "zero-waste" and "circular bioeconomy" for a sustainable future.

Biocompatible green technology principles for the fabrication of food packaging material with noteworthy mechanical and antimicrobial properties A sustainable developmental goal towards the effective, safe food preservation strategy

Biocompatible, eco-friendly, highly economical packaging methods should be needed as conventional packaging is known to cause undesirable effects. As food packaging is the major determining factor of food safety, the selection or methods of packaging materials plays a pioneering role. With this scope, modern food technology seeks unique sustainable approaches for the fabrication of package materials with notable desired properties. The principles, features, and fabrication methodology of modern food packaging are briefly covered in this review. We extensively revealed improved packaging (nanocoating, nanolaminates, and nano clay), active packaging (antimicrobial, oxygen scavenging, and UV barrier packaging), and intelligent/smart packaging (O2 indicator, CO2 indicator, Time Temperature Indicator, freshness indicator, and pH indicator). In particular, we described the role of nanomaterials in the fabrication of packaging material. Methods for the evaluation of mechanical, barrier properties, and anti-microbial assays have been featured. The present studies suggest the possible utilization of materials in the fabrication of food packaging for the production, utilization, and distribution of safe foods without affecting nutritional values.

Environmental Evaluation of Polyhydroxyalkanoates from Animal Slaughtering Waste Using Material Input Per Service Unit

The massive production and extensive use of fossil-based non-biodegradable plastics are leading to their environmental accumulation and ultimately cause health threats to animals, humans, and the biosphere in general. The problem can be overcome by developing eco-friendly ways for producing plastics-like biopolymers from waste residues such as of agricultural origin. This will solve two currently prevailing social issues: waste management and the efficient production of a biopolymer that is environmentally benign, polyhydroxyalkanoates (PHA). The current study assesses the environmental impact of biopolymer (PHA) manufacturing, starting from slaughterhouse waste as raw material. The Material Input Per Service Unit methodology (MIPS) is used to examine the sustainability of the PHA production process. In addition, the impact of shifting from business-as-usual energy provision (i.e., electricity from distribution grid network and heat provision from natural gas) to alternative renewable energy sources is also evaluated. As a major outcome, it is shown that the abiotic material contribution for PHA production process is almost double for using hard coal as an energy source than the petro-plastic low-density-poly(ethene) (LPDE), which PHA shall ultimately replace. Likewise, abiotic material contribution is 43% and 7% higher when using the electricity from the European electricity mix (EU-27 mix) and biogas, respectively, than in the case of LDPE production. However, PHA production based on wind power for energy provision has 12% lower abiotic material input than LDPE. Furthermore, the water input decreases when moving from the EU-27 mix to wind power. The reduction in water consumption for various electricity provision resources amounts to 20% for the EU-27 mix, 25% for hard coal, 71% for wind, and 70% for biogas. As the main conclusion, it is demonstrated that using wind farm electricity to generate PHA is the most environmentally friendly choice. Biogas is the second-best choice, although it requires additional abiotic material input.