Traditional plastic forks and food packaging shed persistent microplastics into the environment, but a Massachusetts-based bioplastics laboratory is scaling up the production of plant-derived alternatives created from fermented sugar. According to reporting from The Associated Press published by U.S. News & World Report, CJ Biomaterials utilizes sugar-fed microbes to manufacture polyhydroxyalkanoates, or PHAs, which are marine and soil biodegradable.
How Plant-Based PHA Biopolymers Are Manufactured
At the CJ Biomaterials research facility in Woburn, Massachusetts, lab technicians pour pebble-sized bioplastic pellets into molding machines to produce test items such as forks and flexible packaging films. According to the company’s marketing director Leah Ford, the production process begins by feeding sugar to microbes that naturally convert it into PHA for energy. Technicians then collect the PHA polymer, transform it into solid granules, and sell the resulting pellets to other companies that melt and mold them into finished commercial goods.
These engineered plant-based polymers maintain structural integrity on store shelves because they remain unexposed to microorganisms in water or soil. However, once discarded into a composting bin, local bacteria colonize the material. Ford noted that a recently tossed-in knife in facility compost bins displayed pitting on the surface as bacteria began consuming the polymer.
Comparing Bioplastic Performance With Conventional Plastics
Lab tests at the Woburn facility show that while some molded PHA forks are too bendy for stabbing a steak, other batches have been rigid, similar to a typical plastic fork. Similarly, technicians successfully roll out flexible films for food packaging—such as a bag for baby carrots—that are quite strong, though not stretchy like cling wrap.
| Material Type | Primary Feedstock | End-of-Life Breakdown | Common Applications |
|---|---|---|---|
| Conventional Plastics | Fossil fuels | Leave persistent microplastics in the environment | Single-use forks, rigid containers, non-recyclable food wraps |
| CJ Biomaterials PHAs | Fermented sugar | Break down within six months | Cutlery, straws, coated cups for hot beverages, frozen food pouches, sushi trays |
Addressing Global Plastic Pollution and Methane Emissions
Concern over microplastics is accelerating interest in marine- and soil-biodegradable alternatives. According to Erin Simon, a vice president at the World Wildlife Fund cited by U.S. News & World Report, biobased plastics are part of a suite of solutions that are needed. Simon emphasizes that the world needs to reduce the amount of plastic being produced, then make the rest sustainably as nations try to confront the plastic pollution crisis by crafting a landmark treaty.
Traditional plastic containers contaminated with food scraps cannot be recycled. Food waste decomposing in landfills emits methane, a potent greenhouse gas that warms the planet. In contrast, a container made of pellets from CJ Biomaterials with food scraps could be sent to a composter.
CJ Biomaterials is part of the $32 billion South Korean conglomerate CJ Group. The enterprise has been producing PHA at a manufacturing facility in Pasuruan, Indonesia, since 2022.
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