🔄 Our planet is choking on plastic pollution, while food packaging are among the main culprits of this crisis. In 2022, each European citizen produced 186.5 kg of packaging waste, which is 29 kg more than in 2011. Of that, 19 % was plastic packaging, and only 41 % of that was recycled. If this trend continues, there could be more plastic than fish in the oceans by weight by 2050.

In response to this problem, a wave of “green” alternatives has appeared on the market. Terms like biodegradable, compostable, recyclable and biobased may sound similar, but they are far from interchangeable. Bioplastics may come from natural sources, but they may not be recyclable or compostable and may contain harmful additives. Many bioplastics only break down under very specific conditions and often contain the notorious PFAS. It is often confusing for citizens to know where to properly separate biodegradable plastic, as instructions vary from municipality to municipality.

But experts say the problem is not just what we use, but how much of it we use. Total packaging waste in the EU has increased by around 20 % over the past decade. That's why the first step is packaging reduction and, where possible, prioritizing reusable solutions, for example in restaurants or delivery.

Still, there is a need for better alternatives to fossil-based plastics. Experts agree that PHA biopolymers are the best candidates for replacing plastics. Within this family, the most promising material is PHB (polyhydroxybutyrate). PHB has better technological properties.

However, the production of these biopolymers from food waste faces significant challenges. These include problems with the pre-treatment of the raw material (waste), logistics, transportation and, most importantly, at cost. Pretreatment, such as deproteinization or fermentation, is expensive and not always scalable. Transporting highly perishable materials to biopolymer factories is difficult. Economically, bioplastic is not yet competitive, as it is much more expensive than conventional plastic without incentives.

It is precisely these challenges that the European ViSS project. Its aim is to sustainably and scalablely produce the biopolymer PHB, free of PFAS, using waste from the poultry and sugar industries. The polymers developed within the ViSS project are biobased and biodegradable in every environment – in soil, freshwater and seawater – because they contain only safe and sustainable ingredients. The innovative approach of the project is that the polymer is designed with the end of its life in mind to ensure safe biodegradation.

The ViSS process uses poultry waste (feathers and bones) and sugar industry by-products, which are sourced locally to reduce transportation costs. Instead of expensive steel reactors, plastic ones are used and the entire process is carried out under non-sterile conditions, further saving costs. The microorganism digests the substrate and accumulates PHBV (poly(3-hydroxybutyrate-co-3-hydroxyvalerate)) in its cells, which is then extracted and purified to produce a biodegradable powder or granules.

The key point of the ViSS process is the hydroxyvalerate content (15 to 30 %) in the product. This makes PHBV less crystalline and gives it flexibility, thus addressing one of the biggest limitations of this type of bioplastic – its brittleness.

If the production of PHBV biopolymer could be scaled up cost-effectively, it would be a real revolution in the world of plastics. However, the last hurdle still remains. priceExperts are calling for policies that would support the bioplastics sector in Europe, so that it is competitive and not 2-3 times more expensive than fossil plastic, nor is it squeezed out by cheaper imports. In short: to give it the strength to put out the fire. Spring

Glossary of key terms:

• Bioplastics: Plastics made from renewable, natural resources.
• Fossil polymers: Polymers derived from fossil fuels (oil, natural gas).
• Bio-basic: Materials derived from renewable, biological sources.
• Biodegradable: Capable of decomposition by natural microorganisms.
• Compostable: Capable of decomposition under specific composting conditions.
• Recyclable: Materials that can be processed and reused.
• PFAS: Per- and polyfluoroalkyl substances; persistent chemicals with potentially harmful effects.
• Endocrine disruption: Chemical interference with the hormonal system.
• PHA (Polyhydroxyalkanoates): A family of biopolymers produced by bacteria.
• PHB (Polyhydroxybutyrate): Type of PHA biopolymer.
• PHBV (Poly(3-hydroxybutyrate-co-3-hydroxyvalerate)): PHB copolymer with added hydroxyvalerate for improved properties.
• Substrate: A substance that microorganisms metabolize.
• Deproteinization: Protein removal.
• Fermentation: Metabolic process in which microorganisms break down substances.
• Additives: Substances added to the base material to improve its properties.
• VisS project: Project focused on sustainable production of PHB biopolymer from poultry and sugar industry waste.
• CETEC: Technology Center in Spain, ViSS project coordinator.
• Hydroxyvalerate: An ingredient added to PHB to increase flexibility (creates PHBV).
• Crystallinity: The degree of order in the molecular structure of a material affects its properties.
• European Union (EU): A political and economic union of 27 member states in Europe.
• REA (Research Executive Agency): Executive Agency of the European Commission.
• UKRI (UK Research and Innovation): UK Research and Innovation Agency.
• Grant No. 101081931: The identification number of the grant funding the research.
• ECOS: Environmental NGO.
• Break Free From Plastic: Global movement against plastic pollution.
• University of Naples Federico II: Italian university.
• Logistics: Managing the flow of goods, information, and other resources between the point of origin and the point of consumption.
• Pretreatment: Processing of raw materials before the main production process.
• Separate collection: Separate waste collection.