Revolutionizing bioplastics: a microbial platform for fully bio-based long-chain polyesters

In a groundbreaking step toward sustainable polymer production, scientists from the Republic of Korea have developed the first end-to-end microbial platform capable of converting renewable plant oils into fully bio-based long-chain polyesters. The research, recently published in the Journal of Bioresources and Bioproducts, demonstrates an integrated approach that may transform the global plastics industry by replacing petroleum-derived materials with renewable, eco-friendly alternatives.

The study, led by Soon Ho Jang and Jung-Oh Ahn, describes a two-step microbial bioconversion process beginning with Candida tropicalis, a yeast engineered to oxidize plant oil-derived n-alkanes into 1,12-dodecanedioic acid (1,12-diacid). The process achieved a remarkable 150 g/L yield with a productivity of 1.53 g/(L·h) in a 5 L bioreactor, later scaled successfully to a 50 L pilot fermenter. In the second step, an engineered Escherichia coli expressing carboxylic acid reductase and phosphopantetheinyl transferase converted the diacid into 1,12-dodecanediol (1,12-diol), reaching 68 g/L with a productivity of 1.42 g/(L·h)—both record-setting results for long-chain monomer biosynthesis.

The two bio-derived monomers were purified with over 98% recovery and subsequently polymerized through solvent-free polycondensation to produce high-quality polyester. Analytical characterization via NMR, DSC, and FTIR confirmed that the resulting polymer exhibited nearly identical structural and thermal properties to its petroleum-based counterpart. Radiocarbon isotope analysis further verified that the material was fully derived from renewable biological carbon sources.

Beyond the laboratory, the team conducted preliminary techno-economic assessments suggesting that bio-based polyester production could be cost-competitive with petrochemical alternatives, especially when utilizing non-food lipid sources such as waste cooking oil or algal oil. The entire workflow—from microbial fermentation to downstream purification and polymer synthesis—was shown to be both scalable and environmentally viable, aligning with global sustainability goals.

This pioneering platform represents a significant milestone in biopolymer research, showcasing how synthetic biology and process engineering can converge to enable a truly circular bioeconomy. As industrial demand for biodegradable and carbon-neutral materials accelerates, this innovation provides a viable pathway toward sustainable manufacturing of high-performance plastics without reliance on fossil fuels.

See the article:

DOI

https://doi.org/10.1016/j.jobab.2025.09.005

Original Source URL

https://www.sciencedirect.com/science/article/pii/S2369969825000659

Journal

Journal of Bioresources and Bioproducts