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WOBURN, Mass. -- At a Massachusetts lab, pebble-sized pellets are transformed into forks and films that won’t leave persistent microplastics in the environment.
These are bioplastic pellets. CJ Biomaterials ferments sugar to make plant-based polymers that microbes will consume. These alternatives to traditional plastics made of fossil fuels are seen by some as one of many solutions needed to confront global plastic pollution.
At the company’s Woburn research facility, lab technicians recently poured pellets into a molding machine to make forks. The test forks were thin enough for home composting, though too bendy for stabbing a steak. Other batches have been rigid, similar to a typical plastic fork. The technicians melted pellets to roll out flexible films for food packaging, like a bag for baby carrots. The film was quite strong but not stretchy like cling wrap.
They are figuring out how their biopolymers can make products with attributes similar to conventional plastics, but that can go in a composting bin instead of a trash can. Forks and films are breaking down in the lab’s compost bin. Straws that were added are long gone. A recently tossed-in knife showed pitting on the surface as bacteria colonized it, starting to consume the material.
Plastics have never really fundamentally been disrupted. Now, interest in bioplastic is growing because of concern over microplastics. It’s the new “wild card” in this market, said the company’s marketing director Leah Ford.
“I’ve been doing this for a long time and the compostability has always been a really strong driver. But with the greater understanding of microplastics, I think, that’s going to change how people think about materials,” she said.
Traditional plastics last for decades or even centuries as they fragment into harmful microplastics and even smaller nanoplastics. Microplastics have been found in the ocean and the air, in our food and water, and in a wide range of body tissues. The Trump administration, while rolling back many environmental regulations, says it will address contamination from microplastics.
Use in packaging
Bioplastics are biobased, meaning they are made completely or partially from a renewable resource, commonly corn or sugar cane; or they are biodegradable, meaning that they break down completely via a natural process. They can also be both, like the polymers made by CJ Biomaterials. It’s a leader in manufacturing polyhydroxyalkanoates, or PHAs, as a polymer that is marine and soil biodegradable.
CJ Biomaterials is trying to replace conventional plastics that are single use or can’t be recycled when contaminated with food scraps. Food waste decomposing in landfills emits methane, a potent greenhouse gas that warms the planet. A container made of pellets from CJ Biomaterials with food scraps could be sent to a composter, unlike a traditional plastic container.
The Woburn lab’s shelves display the company’s successes: compostable cutlery; straws; coated cups for hot beverages and frozen food pouches used in the United States; sushi trays; ramen containers; and reusable paper towels. Lab employees dine with compostable cutlery, drink from compostable cups and make coffee with compostable pods. These products last on shelves because they are not exposed to micro-organisms in water or soil.
CJ Biomaterials feeds sugar to microbes that convert it to PHA for energy. The company collects the PHA and turns it into granules. Pellets of this are then sold to other companies that can melt them down and mold them into products. These same bacteria will consume PHA in a compost pile, breaking it down within six months, Ford said.
CJ Biomaterials is part of the $32 billion South Korean conglomerate CJ Group. It has been producing PHA at a manufacturing facility in Pasuruan, Indonesia, since 2022.
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