1. Research & Development Roadmap
Bio-Based Polymers
Jochen Michels
DECHEMA e.V.
17 March, 2015

2. Research & Development Roadmap
Bio-based plastics are a heterogeneous group:
Roadmap focus
Biodegradable and/or compostable bio-based polymers (e.g. PLA and PHAs)
Non-biodegradable bio-based polymers (e.g. bio-based PE, partially bio-based PET and PTT)
Non-biodegradable thermosets (e.g. partially bio-based polyurethanes and epoxies)
Today, bio-based plastics have an established market and are rapidly growing both in Europe and on a global scale. Between 2008 and 2013, bio-based plastics showed a compound annual growth rate (CAGR) of 20 % in the EU. In 2013, Europe was both the largest bio-based plastics consumer and producer, supplying one third of the global bio-based plastics output.
Concerns about plastic waste problems, GHG emissions and oil price fluctuation are pushing public sectors, businesses, as well as households towards more sustainable alternatives to conventional plastics. Bio-based plastics are a heterogeneous group consisting of:

3. Research & Development Roadmap
Bio-based plastics are a heterogeneous group:
Roadmap focus
Biodegradable and/or compostable bio-based polymers (e.g. PLA and PHAs)
Non-biodegradable bio-based polymers (e.g. bio-based PE, partially bio-based PET and PTT)
Non-biodegradable thermosets (e.g. partially bio-based polyurethanes and epoxies)

4. Research & Development Roadmap
Polylactic acid (PLA)
PLA is produced by chemical polymerisation of lactic acid, which is a anaerobic fermentation product
Fermentation leads to either optically pure L-(+)- or D-(-)-lactic acid, which are the desired sources for the polymerisation
Impurities by its counterpart enantiomer lead to more amorphic polymers with different properties, which are relevant for processing and use

5. Research & Development Roadmap
Polyhydroxyalkanoates (PHA)
PHAs are a group of biodegradable biobased linear polyesters which are produced directly by microbes in an aerobic fermentation process
PHA are intracellular storage substances (as granules)
The most common type of PHA is the homopolymer of 3-hydroxybutyrate (PHB), which became available in the 1980s

6. Research & Development Roadmap
Systematic of Hurdles & Solutions
Hurdles & Solutions
General (horizontal)
Specific for PLA
Specific for PHA
Feedstock supply
Bioconversion
Downstream processing

7. Research & Development Roadmap
Systematic of Hurdles & Solutions
Hurdles & Solutions
General (horizontal)
Specific for PLA
Specific for PHA
Feedstock supply
Bioconversion
Downstream processing

8. Research & Development Roadmap
Main Hurdles and Solutions (general)
Integrate feedstock production and bioconversion to minimize transportation costs and post-harvest losses
Certification of feedstock production against fluctuating feedstock quality (incl. waste)
New (non-food) feedstocks
Develop Biorefinery concepts to valorize the biomass as much as possible
Supply of sufficient amounts of feedstock*
*that compete on price with fossil derived feedstocks

9. Research & Development Roadmap
Main Hurdles and Solutions (specific for PLA & PAH)
Waste streams & by-products like residues from agricultural materials or glycerol from biodiesel production
2nd generation lignocellulosic feedstocks like wood or straw (C6 & C5 conversion)
C1-compounds Syngas-fermentation (CO, CO2, H2)
Complex nitrogen sources like grass press juice
Supply of sufficient amounts of feedstock*
*that compete on price with fossil derived feedstocks

10. Research & Development Roadmap
Main Hurdles and Solutions (general)
Novel microbial production routes for
tolerance to cheap feedstocks and
resistance to by-products and target products
anaerobic fermentation
New enzymes for improved biocatalysis
more active and robust enzymes
engineered bioproduction systems for enzymes
New water management systems
Poor performance and efficiency of bioconversion

11. Research & Development Roadmap
Main Hurdles and Solutions (specific for PLA)
New production strains
higher yield
tolerance against by-products of hydrolysis of 2nd generation feedstocks
Lactate solely fermentation from alt. C-sources without by-products (like acetate)
Optical pure L(+)- or D(-)-lactate fermentation by genetic engineering
Lower pH-Optimum of fermentation minimizes salt and gypsum production
Poor performance and efficiency of bioconversion
3) delete either the D- or L- lactate dehydrogenase genes of the organisms.

12. Research & Development Roadmap
Main Hurdles and Solutions (specific for PAH)
Anaerobic fermentation process
E. coli for anaerobic fermentation
Unsterile, anaerobic fermentation process
S. cerevisiae for anaerobic fermentation
Mixed culture fermentation
Multi phase biological synthesis of PHA
Transgenic plant cells
Poor performance and efficiency of bioconversion
Without by products

13. Research & Development Roadmap
Main Hurdles and Solutions (general)
Modeling of the entire process for maximum product (and space-time) yield
New more efficient bio-catalytic systems (see: bioconversion)
Integrating Bioconversion with DSP also includes chemical conversion
New water management systems
Improved product recovery from water
Minimising water usage
Separation technologies to improve product recovery, contaminant removal and water re-use
High level of im-purities and low product conc. hampers down-stream processing

14. Research & Development Roadmap
Main Hurdles and Solutions (specific for PLA)
High level of im-purities and low product conc. hampers down-stream processing
(Reference to the presentation of Dr. Schulze, TKIS)

15. Research & Development Roadmap
Main Hurdles and Solutions (specific for PAH)
Expensive PHA extraction step*
Environmentally friendly & cost-effective PHA granule recovery steps are needed
e.g. sodium hypochlorite extraction
* Not applicable are:
solvent based extraction (chloroform)
enzyme based biomass digestion
mechanical disruption

16. Non-technological Roadmap
Bio-Based Polymers
Dirk Carrez
Clever Consult bvba
17 March, 2015

17. Non-technological Roadmap
Main hurdles and bottlenecks (as identified by the stakeholders)
Feedstock related barriers
Logistics: securing large quantities of biomass all year round
Seasonability of biomass cropping versus need of continuous feedstock supply
Inefficient transport and distribution of biomass
Inefficient recovery systems for (bio)waste
Feedstock at affordable prices
Costs of feedstock produced in Europe are too high compared to other regions
Varying feedstock prices
(High) import costs for certain types of feedstock
No commonly accepted “sustainability” certification system
Investment barriers and financial hurdles
Capital requirements
Limited availability of public R&D funding
Limited public support for scale-up activities
Limited access to finance for spin-offs and start-ups
Limited access to finance for SMEs
Limited financial support for new production facilities
IB perceived as sector with high investment risk
Too long “return of investment” time
Lack of visible tangible products and blockbusters
Lack of investors’ confidence
Public perception and communication
Poor public perception and awareness of IB and Biobased products
Advantages of biobased products are not visible enough
Negative messages in the media on GMO and biofuels influence perception of IB
Demand side policy barriers
Absence of incentives or efficient policies
No framework to promote biobased products
Lack of a “green public procurement” policy promoting biobased products
Wide variety of ecolabels and no uniform standard present for sustainable and Biobased products

18. Non-technological Roadmap
Main hurdles and solutions
Biobased plastics (e.g. PLA, PHA)
HURDLE
SOLUTIONS
New biobased plastics are often more expensive than the conventional ones
Funding for innovations in order to reduce production costs (e.g. conversion technologies and down-stream processing)
Explain better the benefits of bioplastics, so consumers accept to pay a (bio-)premium
New value chains still have to be developed to obtain critical mass
Develop infrastructure for effective composting or recycling
Development of policy tools to stimulate demand
Need for clear standards and a regulatory framework promoting market uptake
Defining in a transparent way the characteristics: ‘green’, “bio-degradable”, “biobased”, “bioplastics”, etc
Develop clear standards
Improve communication and education
Developing a good programme to stimulate market uptake in Europe (e.g. public procurement)
Lack of financial incentives
Implementing a tax and/or subsidies for certain applications to close the price gap between biobased and fossil based plastics