Requirements on bacterial polyesters as future substitute for conventional plastics for consumer goods

Abstract

Bacterial polyesters such as polyhydroxybutyrate (PHB) or polyhydroxyalkanoates (PHAs) have to pass the following requirements to be accepted on a large scale: (i) they have to fulfil an urgent market need: (ii) they require that new and efficient composting systems are installed in urban areas; (iii) they have to complete with the present plastics as far as quality and processing performance are concerned; (iv) they have to meet the requirement for the registration as food packages; and (v) they have to meet competitive price limits. (i) Some 30% of the plastics in the municipal waste originates from goods which are less than 1 year in use and tend to be heavily soiled by food and feed residues. This part is difficult and expensive to dispose of. Biodegradable alternatives could replace a large part of it. The waste could be diverted from landfills and incineration to composting sites near the end user. The savings in costs and frustrations are the source of a pressing demand for biopolymers, especially for producing goods which do not demand longevity and which are likely to end up soiled with organic matters. (ii) Composting infrastructures exist in rural areas. In urban areas new systems for collecting and composting ‘garden and kitchen wastes’ are being installed for reducing landfill problems, especially in Austria, Denmark, Germany and the Netherlands. These installations give biopolymers a competitive edge in the disposal discussion. (iii) Bacterial polyesters meet various quality and processing performances. They are water-resistant, and goods made of the polyesters are water-tight. The material can be processed by injection and by blow moulding. However, the esters are not flexible enough for forming films or foils. They also tend to become brittle and to lose their vapour barrier properties. It is expected that these limits will be overcome by improving blend formulations. (iv) Bacterial polyesters are not yet allowed for use as food package material. Since the esters represent a novel product, the procedure for the registration poses serious, but no insoluble problems. They require long and costly tests. There are no indications that bacterial polyesters would not attain the requirements. However, they are not expected to serve as food packages in the near future. (v) The present prices for bacterial polyesters are far too high to be accepted on a large scale by the processing and packaging industry. Costs are high mainly because of the raw material prices and to the small-scale production units. They can be lowered to accepted levels by investing in larger units in countries where inexpensive raw materials are available. Thus they will be able to meet the price limits. Since bacterial polyesters increasingly meet the requirements for the penetration of a mass market and since more and more consumers accept composting as an environmentally sound way of recycling organic materials, the polyesters are expected to penetrate a significant part of the short-lived and contaminated plastic products markets by the turn of the century.