Bio-based polymers, such as polyhydroxyalkanoate (PHA), are seeing increasing application as a more sustainable alternative to fossil-based materials. A new, flexible production platform developed by CJ Biomaterials, Inc. (Woburn, Mass.; www.cjbiomaterials.com) is now enabling the production of PHA in both amorphous (aPHA) and semi-crystalline (scPHA) formats, which enables PHA adoption in a wider range of market sectors. “Semi-crystalline PHA offers several benefits over other forms of PHA and competitive products, including better thermostability. Additionally, we have food-contact approval for both scPHA and aPHA products, expanding their potential applications in the food industry,” explains Max Senechal, CJ Biomaterials’ chief commercial officer.
CJ Biomaterials’ new PHA grades can be used in a wide variety of end products (Source: CJ Biomaterials)
CJ Biomaterials developed a specialized aerobic fermentation process to convert natural sugars into scPHA and aPHA. The process can precisely control the production of the co-monomers 3-hydroxybutyrate (3HB) and 4-hydroxybutyrate (4HB). By modifying these ratios, the performance properties can vary from rigid crystalline performance to very flexible with rubber-like qualities. The new process is currently running at a plant in Pasuruan, Indonesia, with a production capacity of 15,000 metric tons per year (m.t./yr). According to the company, its fermentation process enables up to 85% PHA content in microorganisms via engineered microbial strains.
“We can produce crystalline, semi-crystalline and amorphous PHAs by modifying the P3HB and P4HB ratios of our materials. An incredibly broad range of PHA polymers is made possible by this co-monomer ratio control,” says Senechal. CJ Biomaterials’ aPHA and scPHA are included on the U.S. Food and Drug Administration (FDA) Inventory of Effective Food Contact Substances (FCS), meaning that both can be used to manufacture food-contacting packaging materials, including rigid and flexible packaging, straws, cups and other products.