Performing Department
(N/A)
Non Technical Summary
Sustainable Chemicals, LLC (Sust-Chem) was established to address the global plastic pollution crisis. Annually, between 19 to 23 million tons of plastics enter the oceans and by 2050 plastics will contribute 13% of global CO2 emissions. Polyethylene and polypropylene are among the largest volume plastics and constitute 52% of the toxic microplastics found in sediments, which pose potential health risks. Consumers and brand manufacturers seek lower carbon footprint materials with reduced microplastic formation risks, yet viable alternatives for lightweight packaging are scarce. Despite substantial investments, existing bioplastics remain limited to niche markets due to their higher cost and inferior performance than petrochemical plastics. The imperative to replace everyday plastics with eco-friendly alternatives remains unmet.Sust-Chem focuses on developing innovative, fully compostable, and renewable bioplastics. Our approach involves utilizing a plant-based raw material that is 20% cheaper than petrochemical raw materials and can be produced in volumes sufficient to meet the plastic industry's demand. This strategic advantage positions us competitively against both traditional and biobased plastics. Our bioplastics are engineered for optimal circularity and have a benign end-of-life whether recycled, landfilled, or lost in the oceans.This USDA Phase II SBIR project aims to develop a higher performance form of our bioplastics for use in rigid applications such as cosmetic containers, detergent bottles, and soda bottle lids.The market acceptance of Sust-Chem bioplastic will enhance the agriculture sector's role as a reliable supplier of raw materials to the plastic industry, reduce the US dependence on foreign oil, and reduce the environmental impact of thermoplastic manufacture, use, and disposal.
Animal Health Component
50%
Research Effort Categories
Basic
25%
Applied
50%
Developmental
25%
Goals / Objectives
Sustainable Chemicals, LLC develops and commercializes entirely plant-based and compostable plastics to replace conventional polyolefins like polyethylene (PE) and polypropylene (PP). Our bioplastics are made from a bio-based monomer (raw material) that can be produced in large volumes from cellulosic biomass. We engineered our bioplastic for easy chemical recycling (i.e., depolymerization to recover the monomer), but also to have a benign end of life if dispersed to the environment, where it degrades to non-persistent natural molecules that easily convert back to biomass.In prior work, we developed a chemical process to polymerize our monomer into a bioplastic of good flexibility and film-forming properties. This material is currently being developed for the replacement of Low-Density Polyethylene (LDPE) in thin film and soft packaging applications.This USDA SBIR project aims to develop a more regular (higher performance) form of our bioplastics for use in rigid applications such as cosmetic containers, detergent bottles, and soda bottle lids. In the Phase I project, we engineered a specialty enzyme and demonstrated that it can catalyze the polymerization of our biobased monomer to produce a polymeric material. The product is a bioplastic with a higher melting point and higher rigidity (as measured by Young's modulus) than what is obtained by our traditional chemical polymerization process. In Phase II, we plan to optimize and scale our enzymatic polymerization process and complete the characterization of our rigid bioplastics to define applications for first market entry.Sust-Chem bioplastics are made by homo-polymerization of glycoaldehyde dimer, also known as 2,5-dihydroxy-1,4-dioxane (DHDO) to produce poly(2,5-dihydroxy-1,4-dioxane) (PDHDO). The overarching goal of this Phase II project is to optimize and scale up the enzymatic polymerization process and further characterize the properties of tactic (stereoregular) PDHDO.To accomplish this goal we have set the following technical objectives:Scale up the production of the enzyme trehalose phosphorylase to a 100-liter reaction vessel. Optimize and scale up the synthesis of the intermediate DHDO diphosphate.Evaluate the feasibility of enzyme recycling.Optimize and scale up the enzymatic polymerization process.Characterize the chemical structure, mechanical, thermal, and barrier properties of tactic PDHDO.Assess the biodegradability of PDHDO in soil and ocean environments.Carry out a technoeconomic analysis for the enzymatic process.
Project Methods
Enzyme production and polymerization scale-up will be carried out following standardized processes commonly used in industrial research, ensuring reliability and reproducibility. Mechanical and biodegradation testing will be conducted using standardized ASTM methods to accurately assess material properties and environmental impact. Additionally, technoeconomic and life cycle analyses will be performed according to the National Renewable Energy Laboratory (NREL) standardized processes, providing comprehensive evaluations of economic viability and environmental sustainability.