Emerging innovations, sustainable solutions leading the industry

Latest plastic innovations with bioplastics, biodegradables, carbon capture and PCR/PIR are driving sustainable plastics forward, according to Angelica Buan in this report.

Production of plastics has come a long way in reducing environmental impact. Advancements cover the entire lifecycle of plastics, from how they’re made to how they’re disposed of—focusing on producing fewer emissions, enhancing recyclability, and using renewable materials.

Still, scaling up sustainable plastics comes with challenges, including cost, efficiency, and technological limitations. Issues like production scalability, regulatory hurdles, cost reduction, and market acceptance remain key concerns.

Industry players are exploring new solutions to meet sustainability goals, while researchers continue developing technologies to make sustainable plastics a viable mainstream option.

Microorganisms reengineering biodegradable plastics

Biodegradable plastics break down through microbial activity, reducing waste and environmental impact. Derived from renewable resources, petrochemicals, or both, they offer a sustainable alternative to conventional plastics.

Benefits include lower emissions, reduced landfill waste, and composting compatibility, making them useful in packaging, agriculture, and waste management.

Research continues to improve biodegradation efficiency and mechanical properties to rival traditional plastics. Plus, composting can also enhance soil health.

A study by the University of Connecticut (UConn) and bioplastics manufacturer Novamont found that Mater-BiA starch-based polymer degraded by nearly 50% over nine months in a marine setting, exceeding traditional plastics. Published in the Journal of Polymers and the Environment, the study tested Mater-Bi compostable bags in seawater (excluding larger organisms that could interfere with results). The material lost 25% to 47% of its mass or area, with warmer temperatures accelerating the process.

Led by researchers Hannah Collins, Larissa Tabb, and marine sciences professor Evan Ward, the study noted that biodegradable plastics like Mater-Bi could help reduce marine plastic pollution, particularly in aquaculture applications such as kelp farm lines and oyster grow-out bags. The collaboration with Novamont provided insights into real-world biodegradation beyond controlled lab settings.

KAIST’s Microbial Innovation

Beyond biodegradation, researchers are also exploring new ways to develop bioplastics from renewable sources. Scientists at the Korea Advanced Institute of Science & Technology (KAIST) have created a method to produce polyester amide using microorganisms instead of fossil fuels.

KAIST has successfully developed the first microbial production of polyester amide by engineering microbes to produce nine polyester amides from glucose via fermentation.

Polyester amide, a durable plastic-nylon blend, is traditionally petroleum-based and polluting. The KAIST team engineered microbes to produce it from glucose—Earth’s most abundant biomass. Through an optimized fermentation process, they demonstrated potential for large-scale production.

Testing by the Korea Chemical Research Institute confirmed that the bioplastic has properties comparable to HDPE, making it a viable alternative to conventional plastics.

Plastics from Thin Air: Using Carbon Emissions as Feedstock

Conventional petroleum-based plastics are major contributors to greenhouse gas emissions. Currently, plastics account for about 8% of global oil consumption—a figure that could reach 20% by 2050 according to the World Economic Forum.

Using carbon dioxide (CO₂) as a feedstock can reduce environmental impact by decreasing reliance on fossil fuels and lowering emissions. Capturing CO₂ from industrial sources or directly from the atmosphere and converting it into polymers offers a sustainable plastic production alternative.

Fortum Recycling & Waste

Finland-based Fortum Recycling & Waste has developed the world’s first biodegradable plastic made entirely from CO₂ emissions. Their Inga polyhydroxyalkanoate (PHA) material is used in food packaging, electronics, and cosmetics. It is biodegradable, recyclable, and offers excellent barrier properties.

ReSource Chemical Corp

US-based ReSource is developing plastics from CO₂ and agricultural waste. Their technology is based on 2,5-furandicarboxylic acid (FDCA), a molecule that serves as a building block for PEF, a PET resin alternative. PEF is stronger, more durable, and offers better oxygen and moisture barriers.

With funding from Chemical Ventures, Mitsubishi Gas Chemical Company, and others, ReSource has simplified FDCA production by eliminating two-thirds of traditional steps. The tech is based on CO₂ chemistry developed at Stanford University.

FDCA plastics are also safer—FDCA occurs naturally in the human body, making it a non-toxic alternative to current additives. These materials biodegrade more easily and return to their original components faster than conventional plastics.

ReSource plans to build an FDCA pilot plant and expand into specialty chemicals to mainstream FDCA-based materials.

Seeding Innovation in Renewable Materials with Non-Food Feedstock

Materials made from corn starch, sugarcane, and algae are already reducing reliance on fossil fuels. However, Australia-based Ecopha Biotech Pty Ltd claims it has achieved a world-first breakthrough by

Ecopha’s Breakthrough with Pongamia Oil

Ecopha has achieved a world-first by producing PHA from pongamia oil, a sustainable, non-edible resource derived from pongamia tree seeds.

Producing PHA from pongamia oil—a non-edible resource extracted from seeds of the pongamia tree that thrives in arid climates with minimal agricultural inputs—offers a more sustainable alternative to traditional bioplastics.

Unlike biobased plastics made from corn or soy, pongamia oil does not compete with food production. According to Dr. Wilson Ling, CEO of Ecopha, this breakthrough offers economic and environmental advantages.

The company’s patented process qualifies for carbon credits, lowering production costs and making it attractive to industries such as energy, mining, and manufacturing.

Ecopha is commercialising the technology in partnership with Australian design studio Terra Sol. Products include compostable coffee cups, biodegradable lids, eco-friendly straws, and sustainable cutlery. With increasing interest, Ecopha is poised to scale pongamia-based PHA applications.

Recycled Content for Plastic Circularity

Plastics made with recycled content are gaining traction. Repurposing post-consumer and industrial waste reduces reliance on virgin materials and promotes a more sustainable production model.

Spanish energy company Repsol and Tarragona-based Elix Polymers introduced ABS grades with 100% attributed chemically recycled content. Their E-Loop portfolio includes new grades combining both mechanically and chemically recycled materials.

Repsol supplies styrene and butadiene derived from chemically recycled post-consumer waste and bio-circular raw materials, including used cooking oil. These materials meet ISCC Plus certification under a mass balance model. Their partnership was established in 2020.

Rialti’s PP Compound Innovation

European recycled PP producer Rialti has launched PP compounds incorporating 30–40% PCR and 20–40% PIR content, offering a sustainable alternative to virgin polypropylene. These meet End-of-Life Vehicle (ELV) regulations and suit applications in mobility, construction, and home use.

Since being acquired in 2023 by Austrian firm Borealis, Rialti has aligned its offerings with Borealis’ Borcycle M range. According to Shanila Baseley, Vice President of Mobility and Advanced Products at Borealis, these high-performance recycled grades help manufacturers shift toward more sustainable options.