PHA is a bioplastic of natural origin, capable of replacing traditional plastics. It is biodegradable and produced by microorganisms from renewable raw materials. In short, it’s ideal for the green industry of tomorrow. For professionals, understanding the manufacturing process and the benefits of PHA is essential before embarking on their ecological transition.

What is PHA bioplastic?

PHA biopolymers are of microbial origin. They are naturally produced by certain bacteria in response to nutritional stress. These micro-organisms accumulate PHA reserves as a source of energy. This defensive reflex therefore produces matter: PHA. Once harvested and processed, these granules are moulded to make all sorts of objects such as :

• disposable crockery
• organic packaging, bottles and containers
• electronic components
• medical devices
• biomaterials for agriculture and horticulture
• PHA toys
• toys, etc.

PHA: An Ecological Alternative

Unlike traditional petroleum-based plastics, PHA is 100% compostable and biodegradable. In a variety of conditions, even in a marine environment, it deteriorates naturally in just a few weeks. It is also biocompatible and emits no microplastics. In short, a biomaterial that respects the planet and its inhabitants! For industries looking to reduce their environmental footprint, it’s the perfect choice.

The PHA manufacturing process in 5 stages

1. Cultivation of PHA-producing microorganisms

• The process begins with the cultivation and fermentation of bacteria capable of producing PHA. Examples of these microorganisms include Ralstonia eutropha and Bacillus megaterium.

These bacterial species are grown in large-scale fermenters under specific environmental conditions where they are controlled:

• temperature
• oxygen
• humidity

2. Carbon sources

To produce PHA, the bacteria need a carbon source derived from renewable raw materials such as :

• sugars
• vegetable oils
• agricultural or industrial waste

Depending on the source used, the composition of the PHA produced can vary. This allows the mechanical and thermal properties of the bioplastic to be adjusted to meet the specific needs of the industry.

3. Accumulation of PHA in bacterial cells

Bacteria synthesise PHA by accumulating this substance inside their cells in the form of granules. This accumulation process is accelerated by reducing the supply of certain nutrients such as nitrogen. What’s in it for you? To force the bacteria to store PHA as a carbon reserve.

4. PHA extraction

• Once PHA reserves are sufficient, the next step is to extract this bioplastic from the cells using one of two methods:
• chemical solvents: chloroform dissolves the PHA, which is then precipitated for recovery.
• enzymatic methods: these break down the bacterial cell walls without using harmful chemicals.

5. Purification and processing of PHA

After extraction, the PHA is purified to remove impurities and obtain a ready-to-use plastic resin. This bioplastic can then be processed in a similar way to conventional plastics, using injection moulding, extrusion or thermoforming processes.

The challenges of producing PHA

PHA production costs

Let’s face it, PHA manufacturers are faced with a production cost that is still higher than that of traditional plastics. Bacterial fermentation and extraction require complex equipment and processes. In other words, PHA manufacture is the least economically competitive. Preserving the planet remains a challenge in today’s capitalist world…

Technical limitations of PHA

Although PHA has many advantages, its mechanical and thermal properties raise a question. Some of them are still inferior to those of many petroleum-based plastics. For example, PHA may be less resistant to high temperatures or impact. Fortunately, research is underway to improve these properties and broaden the industrial uses of PHA.

The importance of support in the production of PHA

For PHA to become a viable alternative to traditional plastics, it is essential that manufacturers invest. Research and development must also follow. This collaboration between industry, scientists and governments will bring :

• the development of new components
• manufacturing diversity
• more bioplastics products
• optimisation of production processes
• cost reduction

The future of PHA in industry

The PHA market is booming. With significant growth forecast over the coming decades, the trend is green. Logically, increasingly stringent environmental regulations – particularly in Europe – are encouraging the adoption of bioplastics. The packaging, health, agriculture and even automotive industries are beginning to explore their potential. PHA has a wide range of applications, and this new ecological chapter is here to stay.

Companies: what PHA Sourcing can do for you

PHA Sourcing is a key partner in your ecological transition. By offering tailor-made solutions, our company helps manufacturers integrate PHA into their processes. Whether for specific or generic applications, PHA Sourcing provides its expertise and know-how to meet consumer expectations in terms of sustainability and anticipate future environmental regulations.

With PHA Sourcing at your side, the transition to sustainable materials becomes not only possible, but also profitable. We offer sustainable solutions for professionals of all sizes. Contact our teams and let’s get on with your project.