Are bioplastics and plant-based materials safer than conventional plastics? In vitro toxicity and chemical composition

Plastics contain a complex mixture of known and unknown chemicals; some of which can be toxic. Bioplastics and plant-based materials are marketed as sustainable alternative to conventional plastics. However, little is known with regard to the chemicals they contain and the safety of these compounds. Thus, we extracted 43 everyday bio-based and/or biodegradable products as well as their precursors, covering mostly food contact materials made of nine material types, and characterized these extracts using in vitro bioassays and non-target high-resolution mass spectrometry. Two-third (67%) of the samples induced baseline toxicity, 42% oxidative stress, 23% antiandrogenicity and one sample estrogenicity. In total, we detected 41,395 chemical features with 186-20,965 features present in the individual samples. 80% of the extracts contained >1000 features, most of them unique to one sample. We tentatively identified 343 priority compounds including monomers, oligomers, plastic additives, lubricants and non-intentionally added substances. Extracts from cellulose- and starch-based materials generally triggered a strong in vitro toxicity and contained most chemical features. The toxicological and chemical signatures of polyethylene (Bio-PE), polyethylene terephthalate (Bio-PET), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyhydroxyalkanoates (PHA) and bamboo-based materials varied with the respective product rather than the material. Toxicity was less prevalent and potent in raw materials than in final products. A comparison with conventional plastics indicates that bioplastics and plant-based materials are similarly toxic. This highlights the need to focus more on aspects of chemical safety when designing truly "better" plastic alternatives.

Challenges of scaling-up PHA production from waste streams. A review

The search for new materials that replace fossil fuel-based plastics has been focused on biopolymers with similar physicochemical properties to fossil fuel-based plastics, such as Polyhydroxyalkanoates (PHA). The present paper reviews the challenges of scaling-up PHA production from waste streams during the period from 2014 to 2016, focusing on the feasibility of the alternatives and the most promising alternatives to its scaling-up. The reviewed research studies mainly focus on reducing costs or obtaining more valuable polymers. In the future, the integration of PHA production into processes such as wastewater treatment plants, hydrogen production or biodiesel factories could enhance its implementation at industrial scale.

Recent developments in Polyhydroxyalkanoates (PHAs) production - A review

Polyhydroxyalkanoates (PHAs) are inevitably a key biopolymer that has the potential to replace the conventional petrochemical based plastics that pose jeopardy to the environment globally. Even then the reach of PHA in the common market is so restricted. The economy of PHA is such that, even after several attempts the overall production cost seems to be high and this very factor surpasses PHAs usage when compared to the conventional polymers. The major focus of the review relies on the synthesis of PHA from Mixed Microbial Cultures (MMCs), through a 3-stage process most probably utilizing feedstocks from waste streams or models that mimic them. Emphasis was given to the works carried out in the past decade and their coherence with each and every individual criteria (Aeration, Substrate and bioprocess parameters) such that to understand their effect in enhancing the overall production of PHA.

Emerging bone tissue engineering via Polyhydroxyalkanoate (PHA)-based scaffolds

Polyhydroxyalkanoates (PHAs) are a class of biodegradable polymers derived from microorganisms. On top of their biodegradability and biocompatibility, different PHA types can contribute to varying mechanical and chemical properties. This has led to increasing attention to the use of PHAs in numerous biomedical applications over the past few decades. Bone tissue engineering refers to the regeneration of new bone through providing mechanical support while inducing cell growth on the PHA scaffolds having a porous structure for tissue regeneration. This review first introduces the various properties PHA scaffold that make them suitable for bone tissue engineering such as biocompatibility, biodegradability, mechanical properties as well as vascularization. The typical fabrication techniques of PHA scaffolds including electrospinning, salt-leaching and solution casting are further discussed, followed by the relatively new technology of using 3D printing in PHA scaffold fabrication. Finally, the recent progress of using different types of PHAs scaffold in bone tissue engineering applications are summarized in intrinsic PHA/blends forms or as composites with other polymeric or inorganic hybrid materials.

A review on biopolymer production via lignin valorization

Lignin based biopolymer (value added products) production is the most promising technology in the perspective of lignin valorization and sustainable development. Valorization of lignin gain the potentials to produce biopolymers such as polyhydroxyalkanoates, polyhydroxybutyrates, polyurethane etc. However, lignin valorization processes still needs development due to the recalcitrant nature of lignin which restricts its potential to produce valuable products. Many novel extraction strategies have been developed to fragment the lignin structure and make ease the recovery of valuable products. Achieving in depth insights on lignin characteristics and structure will help to understand the metabolic and catalytic degradative pathways needed for lignin valorization. In the view of multipurpose characteristics of lignin for biopolymer production, this review will spot light the potential applications of lignin and lignin based derivatives on biopolymer production, various lignin separation technologies, lignin depolymerization process, biopolymers production strategies and the challenges in lignin valorization will be addressed and discussed.

A spent coffee grounds based biorefinery for the production of biofuels, biopolymers, antioxidants and biocomposites

Spent coffee grounds are composed of lipid, carbohydrates, carbonaceous, and nitrogen containing compounds among others. Using n-hexane and n-hexane/isopropanol mixture highest oil yield was achived during soxhlet extraction of oil from spent coffee grounds. Alternatively, supercritical carbon dioxide can be employed as a green solvent for the extraction of oil. Using advanced chemical and biotechnological methods, spent coffee grounds are converted to various biofuels such as, biodiesel, renewable diesel, bioethanol, bioethers, bio-oil, biochar, and biogas. The in-situ transesterification of spent coffee grounds was carried out in a large scale (4 kg), which led to 80-83% biodiesel yield. In addition, a large number of value added and diversified products viz. polyhydroxyalkanoates, biosorbent, activated carbon, polyol, polyurethane foam, carotenoid, phenolic antioxidants, and green composite are obtained from spent coffee grounds. The principles of circular economy are applied to develop a sustanaible biorefinery based on valorisation of spent coffee grounds.

Polyhydroxyalkanoates: Trends and advances toward biotechnological applications

Plastics are an integral part of most of the daily requirements. Indiscriminate usage and disposal have led to the accumulation of massive quantities of waste. Their non-biodegradable nature makes it increasingly difficult to manage and dispose them. To counter this impending disaster, biodegradable polymers, especially polyhydroxy-alkanoates (PHAs), have been envisaged as potential alternatives. Owing to their unique physicochemical characteristics, PHAs are gaining importance for versatile applications in the agricultural and medical sectors. Applications in the medical sector are more promising because of their commercial viability and sustainability. Despite such potential, their production and commercialization are significant challenges. The major limitations are their poor mechanical strength, production in small quantities, costly feed, and lack of facilities for industrial production. This article provides an overview of the contemporary progress in the field, to attract researchers and stakeholders to further exploit these renewable resources to produce biodegradable plastics on a commercial scale.

Biowaste-to-bioplastic (polyhydroxyalkanoates): Conversion technologies, strategies, challenges, and perspective

Biowaste management is a challenging job as it is high in nutrient content and its disposal in open may cause a serious environmental and health risk. Traditional technologies such as landfill, bio-composting, and incineration are used for biowaste management. To gain revenue from biowaste researchers around the world focusing on the integration of biowaste management with other commercial products such as volatile fatty acids (VFA), biohydrogen, and bioplastic (polyhydroxyalkanoates (PHA)), etc. PHA production from various biowastes such as lignocellulosic biomass, municipal waste, waste cooking oils, biodiesel industry waste, and syngas has been reported successfully. Various nutrient factors i.e., carbon and nitrogen source concentration and availability of dissolved oxygen are crucial factors for PHA production. This review is an attempt to summarize the recent advancements in PHA production from various biowaste, its downstream processing, and other challenges that need to overcome making bioplastic an alternate for synthetic plastic.

Recovery of polyhydroxyalkanoates (PHAs) from wastewater: A review

Polyhydroxyalkanoates (PHAs) are biopolyesters accumulated as carbon and energy storage materials under unbalanced growth conditions by various microorganisms. They are one of the most promising potential substitutes for conventional non-biodegradable plastics due to their similar physicochemical properties, but most important, its biodegradability. Production cost of PHAs is still a great barrier to extend its application at industrial scale. In order to reduce that cost, research is focusing on the use of several wastes as feedstock (such as agro-industrial and municipal organic waste and wastewater) in a platform based on mixed microbial cultures. This review provides a critical illustration of the state of the art of the most likely-to-be-scale-up PHA production processes using mixed microbial cultures platform and waste streams as feedstock, with a particular focus on both, upstream and downstream processes. Current pilot scale studies, future prospects, challenges and developments in the field are also highlighted.

Waste to bioplastics: How close are we to sustainable polyhydroxyalkanoates production?

Increased awareness of environmental sustainability with associated strict environmental regulations has incentivized the pursuit of novel materials to replace conventional petroleum-derived plastics. Polyhydroxyalkanoates (PHAs) are appealing intracellular biopolymers and have drawn significant attention as a viable alternative to petrochemical based plastics not only due to their comparable physiochemical properties but also, their outstanding characteristics such as biodegradability and biocompatibility. This review provides a comprehensive overview of the recent developments on the involved PHA producer microorganisms, production process from different waste streams by both pure and mixed microbial cultures (MMCs). Bio-based PHA production, particularly using cheap carbon sources with MMCs, is getting more attention. The main bottlenecks are the low production yield and the inconsistency of the biopolymers. Bioaugmentation and metabolic engineering together with cost effective downstream processing are promising approaches to overcome the hurdles of commercial PHA production from waste streams.

Capture-Ferment-Upgrade: A Three-Step Approach for the Valorization of Sewage Organics as Commodities

This critical review outlines a roadmap for the conversion of chemical oxygen demand (COD) contained in sewage to commodities based on three-steps: capture COD as sludge, ferment it to volatile fatty acids (VFA), and upgrade VFA to products. The article analyzes the state-of-the-art of this three-step approach and discusses the bottlenecks and challenges. The potential of this approach is illustrated for the European Union's 28 member states (EU-28) through Monte Carlo simulations. High-rate contact stabilization captures the highest amount of COD (66-86 g COD person equivalent^-1 day^-1 in 60% of the iterations). Combined with thermal hydrolysis, this would lead to a VFA-yield of 23-44 g COD person equivalent^-1 day^-1. Upgrading VFA generated by the EU-28 would allow, in 60% of the simulations, for a yearly production of 0.2-2.0 megatonnes of esters, 0.7-1.4 megatonnes of polyhydroxyalkanoates or 0.6-2.2 megatonnes of microbial protein substituting, respectively, 20-273%, 70-140% or 21-72% of their global counterparts (i.e., petrochemical-based esters, bioplastics or fishmeal). From these flows, we conclude that sewage has a strong potential as biorefinery feedstock, although research is needed to enhance capture, fermentation and upgrading efficiencies. These developments need to be supported by economic/environmental analyses and policies that incentivize a more sustainable management of our resources.

An urban biorefinery for food waste and biological sludge conversion into polyhydroxyalkanoates and biogas

This study focuses on the application of the concept of circular economy, with the creation of added-value marketable products and energy from organic waste while minimizing environmental impacts. Within this purpose, an urban biorefinery technology chain has been developed at pilot scale in the territorial context of the Treviso municipality (northeast Italy) for the production of biopolymers (polyhydroxyalkanoates, PHAs) and biogas from waste of urban origin. The piloting system (100-380 L) comprised the following units: a) acidogenic fermentation of the organic fraction of municipal solid waste (OFMSW) and biological sludge; b) two solid/liquid separation steps consisting of a coaxial centrifuge and a tubular membrane (0.2 μm porosity); c) a Sequencing Batch Reactor (SBR) for aerobic PHA-storing biomass production; d) aerobic fed-batch PHA accumulation reactor and e) Anaerobic co-digestion (ACoD). The thermal pre-treatment (72 °C, 48 h) of the feedstock enhanced the solubilization of the organic matter, which was converted into volatile fatty acids (VFAs) in batch mode under mesophilic fermentation conditions (37 °C). The VFA content increased up to 30 ± 3 g COD/L (overall yield 0.65 ± 0.04 g COD_VFA/g VS₍₀₎), with high COD_VFA/COD_SOL (0.86 ± 0.05). The high COD_VFA/COD_SOL ratio enhanced the PHA-storing biomass selection in the SBR by limiting the growth of the non-storing microbial population. Under fully aerobic feast-famine regime, the selection reactor was continuously operated for 6 months at an average organic loading rate (OLR) of 4.4 ± 0.6 g COD/L d and hydraulic retention time (HRT) of 1 day (equal to SRT). The ACoD process (HRT 15 days, OLR 3.0-3.5 kg VS/m³ d) allowed to recover the residual solid-rich overflows generated by the two solid/liquid separation units with the production of biogas (SGP 0.44-0.51 m³/kg VS) and digestate. An overall yield of 7.6% wt PHA/VS₍₀₎ has been estimated from the mass balance. In addition, a preliminary insight into potential social acceptance and barriers regarding organic waste-derived products was obtained.

Bioconversion of waste (water)/residues to bioplastics- A circular bioeconomy approach

Research insight into the technical challenges of bioplastics production has revealed their confoundedness in their niche markets and struggles to enter the mainstream. There is an increasing problem of waste disposal and high cost of pure substrates in polyhydroxyalkanoates (PHA) production. This has led to the future need of upgrading the waste streams from different industries into the role of feedstocks for production of PHA. The review covers the latest developments in using wastes and surplus materials for PHA production. In addition to inexpensive carbon sources, efficient upstream and downstream processes and recycling of waste streams within the process are required to maintain the circularity in the entire process. A view on the link between circular bioeconomy and PHA production process covering the techno-economic, life cycle assessment and environmental aspects has also been provided. Furthermore, the future perspectives related to the topic have also been discussed.

Production of polyhydroxyalkanoates on waste frying oil employing selected Halomonas strains

The aim of this work was to study the potential of selected Halomonas species for conversion of waste frying oil into polyhydroxyalkanoates (PHA). In total nine Halomonas strains were experimentally screened for their capability of PHA production. Among them, Halomonas neptunia and Halomonas hydrothermalis were identified as potent PHA producers. Initial concentration of NaCl was identified as parameter influencing PHA yields as well as molecular weight of the polymer. In addition, H. hydrothermalis was capable of biosynthesis of a copolymer of 3-hydroxybutyrate and 3-hydroxyvalerate P(3HB-co-3HV). When valerate was utilized as a precursor, the 3HV fraction in the copolymer reached high values of 50.15 mol.%. PHA production on lipid substrates by Halomonas has not been reported so far. Bearing in mind all the positive aspects of employing extremophiles in industrial biotechnology, H. hydrothermalis seems to be a very interesting halophilic strain for production of PHA using lipid substrates.

Polyhydroxyalkanoate (PHA) production via resource recovery from industrial waste streams: A review of techniques and perspectives

The problem of waste generation in the form of wastewater and solid wastes has caused an urgent, yet persisting, global issue that calls for the development of sustainable treatment and resource recovery technologies. The production of value-added polyhydroxyalkanoates (PHAs) from industrial waste streams has attracted the attention of researchers and process industries because they could replace traditional plastics. PHAs are biopolymers with high degradability, with a variety of applications in the manufacturing sector (e.g. medical equipment, packaging). The aim of this review is to describe the techniques and industrial waste streams that are applied for PHA production. The different enrichment and accumulation techniques that employ mixed microbial communities and carbon recovery from industrial waste streams and various downstream processes were reviewed. PHA yields between 7.6 and 76 wt% were reported for pilot-scale PHA production; while, at the laboratory-scale, yields from PHA accumulation range between 8.6 and 56 wt%. The recent advances in the application of waste streams for PHA production could result in more widely spread PHA production at the industrial scale via its integration into biorefineries for co-generation of PHAs with other added-value products like biohydrogen and biogas.

The underexplored role of diverse stress factors in microbial biopolymer synthesis

Polyhydroxyalkanoates (PHA) are microbial polyesters which, apart from their primary storage role, enhance the stress robustness of PHA accumulating cells against various stressors. PHA also represent interesting alternatives to petrochemical polymers, which can be produced from renewable resources employing approaches of microbial biotechnology. During biotechnological processes, bacterial cells are exposed to various stressor factors such as fluctuations in temperature, osmolarity, pH-value, elevated pressure or the presence of microbial inhibitors. This review summarizes how PHA helps microbial cells to cope with biotechnological process-relevant stressors and, vice versa, how various stress conditions can affect PHA production processes. The review suggests a fundamentally new strategy for PHA production: the fine-tuned exposure to selected stressors, which might be used to boost PHA production and even to tailor their structure.

Biopolymer poly-hydroxyalkanoates (PHA) production from apple industrial waste residues: A review

Apple pomace, the residue which is left out after processing of apple serves as a potential carbon source for the production of biopolymer, PHA (poly-hydroxyalkanoates). It is rich in carbohydrates, fibers and polyphenols. Utilization of these waste resources has dual societal benefit-waste management and conversion of waste to an eco-friendly biopolymer. This will lower the overall economics of the process. A major limitation for the commercialization of biopolymer in comparison with petroleum derived polymer is the high cost. This article gives an overview of valorization of apple pomace for the production of biopolymer, various strategies adopted, limitations as well as future perspectives.

Production of polyhydroxyalkanoates (PHA) by a thermophilic strain of Schlegelella thermodepolymerans from xylose rich substrates

The aim of this work was to investigate the thermophilic bacterium Schelegelella thermodepolymerans DSM 15344 in terms of its polyhydroxyalkanoates (PHA) biosynthesis capacity. The bacterium is capable of converting various sugars into PHA with the optimal growth temperature of 55 °C; therefore, the process of PHA biosynthesis could be robust against contamination. Surprisingly, the highest yield was gained on xylose. Results suggested that S. thermodepolymerans possess unique xylose metabolism since xylose is utilized preferentially with the highest consumption rate as compared to other sugars. In the genome of S. thermodepolymerans DSM 15344, a unique putative xyl operon consisting of genes responsible for xylose utilization and also for its transport was identified, which is a unique feature among PHA producers. The bacterium is capable of biosynthesis of copolymers containing 3-hydroxybutyrate and also 3-hydroxyvalerate subunits. Hence, S.thermodepolymerans seems to be promising candidate for PHA production from xylose rich substrates.

Chemoautotroph Cupriavidus necator as a potential game-changer for global warming and plastic waste problem: A review

Cupriavidus necator, a versatile microorganism found in both soil and water, can have both heterotrophic and lithoautotrophic metabolisms depending on environmental conditions. C. necator has been extensively examined for producing Polyhydroxyalkanoates (PHAs), the promising polyester alternatives to petroleum-based synthetic polymers because it has a superior ability for accumulating a considerable amount of PHAs from renewable resources. The development of metabolically engineered C. necator strains has led to their application for synthesizing biopolymers, biofuels and biochemicals such as ethanol, isobutanol and higher alcohols. Bio-based processes of recombinant C. necator have made much progress in production of these high-value products from biomass wastes, plastic wastes and even waste gases. In this review, we discuss the potential of C. necator as promising platform host strains that provide a great opportunity for developing a waste-based circular bioeconomy.

Scaling-up microbial community-based polyhydroxyalkanoate production: status and challenges

Conversion of organic waste and wastewater to polyhydroxyalkanoates (PHAs) offers a potential to recover valuable resources from organic waste. Microbial community-based PHA production systems have been successfully applied in the last decade at lab- and pilot-scales, with a total of 19 pilot installations reported in the scientific literature. In this review, research at pilot-scale on microbial community-based PHA production is categorized and subsequently analyzed with focus on feedstocks, enrichment strategies, yields of PHA on substrate, biomass PHA content and polymer characterization. From this assessment, the challenges for further scaling-up of microbial community-based PHA production are identified.

A comprehensive review on recent advancements in biodegradation and sustainable management of biopolymers

Recent years have seen upsurge in plastic manufacturing and its utilization in various fields, such as, packaging, household goods, medical applications, and beauty products. Due to various adverse impacts imposed by synthetic plastics on the health of living well-being and the environment, the biopolymers have been emerged out an alternative. Although, the biopolymers such as polyhydroxyalkanoates (PHA) are entirely degradable. However, the other polymers, such as poly (lactic acid) (PLA) are only partially degradable and often not biosynthesized. Biodegradation of the polymers using microorganisms is considered an effective bioremediation approach. Biodegradation can be performed in aerobic and anaerobic environments. In this context, the present review discusses the biopolymer production, their persistence in the environment, aerobic biodegradation, anaerobic biodegradation, challenges associated with biodegradation and future perspectives. In addition, this review discusses the advancement in the technologies associated with biopolymer production, biodegradation, and their biodegradation standard in different environmental settings. Furthermore, differences in the degradation condition in the laboratory as well as on-site are discussed.

A review on production of polyhydroxyalkanoate (PHA) biopolyesters by thermophilic microbes using waste feedstocks

Polyhydroxyalkanoates (PHAs) are produced by numerous microbes as a subcellular energy source. Despite of their diverse applications, exorbitant production cost limits their commercial synthesis. Apart from various cost determining factors such as cost-effective feedstocks or economic recovery methods, the use of appropriate bacteria holds the key to reduce the fermentation economics. Extremophiles, especially thermophilic PHA producers, could make the bioprocess economically viable by reducing the production cost in several aspects. Using variety of waste feedstocks as carbon substrates could open the way for the valorisation of industrial waste streams and cost-effective PHA production. Therefore, the article critically reviews the current knowledge of the synthesis of PHA polyesters in thermophilic conditions. Additionally, it summarises several studies on thermophilic PHA producing bacteria grown on various waste substrates. To conclude, the paper focuses on screening and recovery methods as well as technical challenges in thermophilic PHA production.

A review on the conversion of volatile fatty acids to polyhydroxyalkanoates using dark fermentative effluents from hydrogen production

The production of bio/microbial-based polymers, polyhydroxyalkanoates (PHAs) from volatile fatty acids (VFAs) of dark fermentative effluents in the bio-H₂ reactor is being paid attention, owing to their commercial demand, applications and as carbon as well as energy storage source. Since, they are the cheap precursors for such valuable renewable biopolymers which all possess the properties; those are analogous to the petro-derived plastics. Several studies were stated, related to the consumption of both individual and mixed VFAs for the potential PHAs production. Their biodegradability nature makes them extremely desirable alternative to fossil-derived synthetic polymers. In this regard, this review summarizes the use of bio-based PHAs production via both microbial and biochemical pathways using dark fermentative bio-H₂ production from waste streams as feedstock. Furthermore, this review deals the characteristics, synthesis and production of the bio-based PHAs along with their co-polymers and applications to give an outlook on future research.

Microbial polyhydroxyalkanoate production from lignin by Pseudomonas putida NX-1

Biological approaches play an important role in lignin valorization, whereas many issues in this area remain unclear. Herein, ligninolytic enzymes in Pseudomonas putida NX-1 were systematically unraveled based on genome sequence technology. Particularly, a dye-decolorizing peroxidase was systematically studied by heterologous expression, enzyme purification, and enzymatic characterization, which suggested it possessed activities on both synthetic dyes and lignin-derived aromatics. Moreover, a complete pathway for polyhydroxyalkanoate biosynthesis was annotated, and the polyhydroxyalkanoate biosynthesis capability of P. putida NX-1 was experimentally confirmed with lignin as the sole carbon source. Furthermore, the monomer compositions, molecular weights, and thermal properties of polyhydroxyalkanoate from glucose and lignin-derived aromatics were comprehensively determined by gas chromatography-mass spectrometry, gel permeation chromatography, differential scanning calorimetry, and thermogravimetric analysis. The results indicated that physical properties of polyhydroxyalkanoate prepared from glucose and lignin-derived aromatics were similar, which suggested lignin could be an alternative feedstock for polyhydroxyalkanoate production without compromising its quality.

Engineering microbial division of labor for plastic upcycling

Plastic pollution is rapidly increasing worldwide, causing adverse impacts on the environment, wildlife and human health. One tempting solution to this crisis is upcycling plastics into products with engineered microorganisms; however, this remains challenging due to complexity in conversion. Here we present a synthetic microbial consortium that efficiently degrades polyethylene terephthalate hydrolysate and subsequently produces desired chemicals through division of labor. The consortium involves two Pseudomonas putida strains, specializing in terephthalic acid and ethylene glycol utilization respectively, to achieve complete substrate assimilation. Compared with its monoculture counterpart, the consortium exhibits reduced catabolic crosstalk and faster deconstruction, particularly when substrate concentrations are high or crude hydrolysate is used. It also outperforms monoculture when polyhydroxyalkanoates serves as a target product and confers flexible tuning through population modulation for cis-cis muconate synthesis. This work demonstrates engineered consortia as a promising, effective platform that may facilitate polymer upcycling and environmental sustainability.