CO2 & Waste-Derived Bioplastics: Pioneering Sustainable Manufacturing

As the world grapples with the environmental impact of traditional plastics, bioplastics derived from carbon dioxide (CO₂) and waste materials present a promising solution. This emerging sustainable market seeks to address two critical global challenges: reducing greenhouse gas emissions and managing waste. By converting CO₂ and waste into useful bioplastics, scientists and companies are pioneering technologies that could revolutionize the way we produce and consume plastics.

In IDTechEx’s recently published market research report covering the bioplastics market “Bioplastics 2025-2035: Technology, Market, Players, and Forecasts”, the full spectrum of plastics derived from biobased feedstocks and non-biodegradable plastics is examined.

Understanding the Problem: Plastics, CO₂, and Waste

Traditional plastics are primarily derived from fossil fuels, such as petroleum and natural gas. The production of these plastics is energy-intensive and contributes significantly to greenhouse gas emissions. According to the World Economic Forum, the plastics industry is responsible for approximately 8% of global oil consumption, a figure projected to rise to 20% by 2050 if current trends continue.

Moreover, plastic waste is a severe environmental issue. Over eight million tonnes of plastic end up in the oceans every year, harming marine life and ecosystems. Only about 9% of plastic is recycled globally, with the rest ending up in landfills or the environment. The dual challenge of managing waste and reducing CO₂ emissions has led to exploring alternative solutions, including developing bioplastics from CO₂ and waste materials.

CO₂-Derived Bioplastics

Converting CO₂ into bioplastics involves capturing carbon dioxide from industrial emissions or directly from the atmosphere and using it as a feedstock to produce polymers. This approach aims to reduce the amount of CO₂  released into the atmosphere and creates an abundant source of raw material for plastic production.

One example of this technology is the work being done by Newlight Technologies. Based in California, Newlight has developed a process that captures CO₂ from the air and combines it with methane from agricultural waste to produce a bioplastic called AirCarbon. AirCarbon is a thermoplastic used in various applications, from packaging to furniture. According to Newlight, for every kilogram of AirCarbon produced, 88 kilograms of CO₂ are sequestered, effectively turning carbon pollution into a valuable resource.

Similarly, Covestro, a German materials science company, has been working on using CO₂ as a raw material for producing polyols, a key component in polyurethane plastics. Their product, called cardyon^®, incorporates up to 20% CO₂ . This approach exemplifies how CO₂ can be transformed from an undesired product into a valuable resource, contributing to a circular economy.

Waste-Derived Bioplastics

Another emerging avenue in the bioplastics industry is converting waste materials into bioplastics. These approaches aim to address the demand for sustainable plastics and the need to utilize waste streams.

Many market players are aiming to utilize this approach to producing bioplastics. For example, Mango Materials, a California-based company, produces biodegradable bioplastics from methane, a greenhouse gas released from sources such as landfills and wastewater treatment plants. The methane is used to create polyhydroxyalkanoates (PHA), a biodegradable bioplastic. Other companies, like Biofase, manufacture plastics from avocado waste. Paques Biomaterials, a division of the Dutch company Paques, focuses on converting wastewater and organic residues into biodegradable plastics, mainly PHA. AgroRenew, meanwhile, converts agricultural waste, including watermelon, pumpkin, and cantaloupe residues, into fully biodegradable plastics using a process that breaks down crop waste into fine micron dust, which is then transformed into biopolymers.

While the concept of producing bioplastics from waste materials offers a seemingly sustainable solution to both plastic production and waste management, it is not without challenges and potential drawbacks. Critics argue that the process of converting waste into bioplastics can be resource-intensive, requiring significant energy and water, which may offset the environmental benefits. Additionally, the infrastructure needed to collect, process, and refine diverse waste streams can be costly and inefficient, leading to questions about the overall scalability and economic viability of these technologies.

Sustainability and Scalability

CO₂ -to-plastic and waste-derived bioplastics offer a way to reduce the environmental impact of plastics by using CO₂ and waste as feedstocks, cutting reliance on fossil fuels and reducing greenhouse gas emissions. However, the scalability of these technologies remains a key challenge. While companies like Newlight Technologies and Covestro have demonstrated the feasibility of these processes, scaling them up to meet global demand will require significant investment and innovation.

The cost of producing bioplastics from CO₂ and waste is currently higher than that of traditional plastics, which will strongly limit their adoption in the short term. Moreover, the infrastructure for capturing CO₂ and processing waste into bioplastics needs to be developed and integrated into existing manufacturing systems. The key challenge will be competition from other bioplastics that can be produced with fewer scaling limitations and, therefore, at a likely more competitive price.

Collaboration between governments, industry, and research institutions will be crucial to overcoming scalability and cost challenges. Policy incentives, such as carbon pricing and subsidies for sustainable materials, could help accelerate the adoption of bioplastics. Additionally, continued investment in research and development will be essential to improving the efficiency and scalability of these processes.

In conclusion, CO₂ -derived and waste-derived bioplastics represent a potentially promising solution to two of the most pressing environmental challenges of our time: reducing greenhouse gas emissions and managing waste. While there are significant hurdles to overcome, the potential benefits of these technologies make them a critical area of focus for the future of sustainable manufacturing. As companies continue to innovate and scale these processes, bioplastics from these sources could play a key role in building a more sustainable and circular economy.

Bioplastics Market Forecast

IDTechEx is showcasing its newest and most extensive market report yet on bioplastics entitled “Bioplastics 2025-2035: Technologies, Markets, Players, and Forecasts”. The report looks to analyze the effect of regulations and more by covering in depth the bioplastics market, including independent analysis of technology developments and trends, plant capacities, industry news, company landscapes, market information, partnership information, and segmented polymer production forecasts.