Results in Engineering (Jun 2025)
Polyhydroxyalkanoates (PHAs): Key Challenges in production and sustainable strategies for cost reduction within a circular economy framework
Abstract
The growing concern over plastic pollution and the environmental effects of conventional plastics has spurred the bioplastics innovation, with polyhydroxyalkanoates (PHAs) emerging as a promising alternative due to their biodegradability and wide-ranging applications in various industries. The high production costs associated with PHAs have hindered their commercial viability, limiting their adoption on a large scale. PHA production costs range from $4–6/kg, compared to $1–2/kg for petrochemical plastics. This review provides a comprehensive analysis of the challenges and cost reduction strategies in PHA production. Key obstacles such as the high cost of raw materials, limited substrate availability, low yield, scalability issues, and complex downstream processing are discussed in detail. The review highlights innovative strategies to mitigate these challenges, including the optimization of low-cost carbon sources, the integration of waste-to-resource approaches, and the engineering of microbial strains for enhanced yield and substrate versatility. Advancements in fermentation process optimization, along with novel downstream processing solutions such as cost-effective extraction methods, green solvents, and solvent recycling, are explored to further reduce production costs. By integrating recent research advancements and innovations in the field, this review paper aims to provide a holistic perspective on the economic challenges and solutions for making PHA production more cost-effective, thereby contributing to the broader goal of sustainable bioplastics and the reduction of environmental plastic pollution.
