Bioresour Technol. 2025 May 31. pii: S0960-8524(25)00711-4. [Epub ahead of print]433 132745
In light of the growing severity of plastic pollution and the fossil resource crisis, replacing conventional fossil-based plastics with bio-based and biodegradable "green plastics" is imperative. Polyhydroxyalkanoates (PHAs), which are synthesized by microorganisms, are considered to be the most promising candidates due to their good biodegradability and material properties. However, their widespread commercial adoption is hindered by their high production costs. To develop low-cost PHA synthesis processes, it is necessary to fully evaluate the successes and the limitations of current technologies. This review summarizes recent advancements in reducing PHA production costs, focusing on the development of low-cost carbon sources, strain engineering, extremophilic PHA fermentation, and mixed microbial cultures (MMCs) fermentation. Among low-cost carbon sources, lignocellulosic biomass, owing to its abundant availability, shows greater potential for driving economically viable, large-scale PHA production. However, current pure-culture fermentation processes face challenges such as low carbon conversion efficiency and susceptibility to inhibitors when utilizing lignocellulosic feedstocks. Strain engineering offers promising solutions to these challenges through strategies such as ribosome-binding site optimization, promoter optimization, metabolic engineering, and cell morphology engineering. In contrast to pure-culture fermentation, MMCs-based fermentation, which operates in open environments, demonstrates superior economic feasibility. Future research should focus on refining protocols for MMCs enrichment and establishing continuous, high-efficiency PHA production systems tailored to industrial requirements. Additionally, the PHA recovery protocols need to be optimized to minimize the chemical usage for economic viability and environmental sustainability.
Keywords: Cost reduction; Lignocellulosic biomass; Mixed microbial culture; Polyhydroxyalkanoates; Pure culture; Synthetic biology