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Commercial Success of ECLAIR Programme
AGRE-0006: Novel biosynthetic routes for, and biodegradation of, polyhydroxy alkanoates made by genetically engineered strains of bacteria and plants |
Science Background
A number of species of bacteria produce granules of material within their cells which have the properties of thermoformable plastics and which are both biodegradable and compatible with living system. These have applications in medicine, as packaging or as horticultural mulches. The main barriers are cost-related. These can be overcome by increasing productivity, simplifying the process and extending the range of materials.
Objectives
This project aimed to overcome economic barriers for production of polyhydroxy alkanoates (including poly-ß-hydroxybutyrate – PHB and its copolymer hydroxyvaleric acid – PHB/v) by focusing on the microorganisms that produce such materials and the biochemistry and genetics of the synthetic pathways. It also extended to examination of biodegradation in a number of environmental situations.
Significant changes and results since end of ECLAIR
ICI (UK) launched Biopol® resin in 1990. This was developed from a biodegradable polyester comprising copolymers of poly-hydroxy-butyrate/valerate (PHB/V) and is produced by the bacterium Alcaligenes eutrophus in a fermentation process using sugar as the main raw material. Further development and product launches followed after the Biopol® business was transferred to Zeneca Ltd as a result of the demerger of ICI pharmaceuticals and agrochemicals in 1993. In 1996, the Biopol® business unit was acquired from Zeneca by Monsanto (Belgium) and in 1997/1998 its contribution to Monsanto’s corporate goals was recognized by the winning of a Monsanto Pledge Award (Market place Category) for leadership in this field. Monsanto’s researched included investigations into whether plants such as switchgrass, sugar can or corn could be genetically modified to produce commercial quantities of Biopol in targeted tissues. In 1997/1998 Biopol® was produced as a guest operation at NutraSweet Kelco Company, Knowsley (a Monsanto subsidiary). However, in order to fund buying of seed businesses, Monsanto made substantial cutbacks in November 1998 and announced that they were scrapping a number of small businesses, including Biopol®, in February 1999.
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The world’s first biodegradable credit card was made from Biopol®. The Greenpeace Visa card was launched in May 1997 and Monsanto claimed it decomposed in compost within 12 weeks. |
Results
At end of this ECLAIR project
Knowledge of the pathways through which PHAs are produced in a number of organisms (Pseudomonas, Alcaligenes and Rhodococcus) and new strains of these organisms were isolated. PHB genes were expressed in rape and tobacco. Data on the mechanism and organisms involved in biodegradation of PHB and related polymers was collected, reflecting locations in which products might be used, discarded or disposed of (soil, landfills, sewage works, etc). The first commercial product (a shampoo bottle) using Biopol® resin was launched by the coordinators in 1990.
Current position
Although Monsanto made breakthroughs related to Biopol®, it does not think the technology will be economically feasible for several years. Due to in-house cutbacks they have stopped trying to genetically engineer plants to make plastic.
Impact
Commercial
Biopol® is a versatile polymer material that can be used in a wide variety of applications, including injection and extrusion moldings, thermoformed sheet, coatings on paper and board, and blown film. A number of products have been commercialized in both Europe and Japan, including cosmetic bottles, coated board drink cups and water denitrification filter balls. In 1993 Zeneca, K.K. was supplying Biopol®, which was produced at the company’s UK plant. Approximately 50% of sales, from a capacity of 300 tons in 1992 and 600 tons in 1993, were sold in Japan. Biopol® received industry awards in 1996 (for cups) and 1997 (for a commercial biodegradable credit card). Monsanto believes that there is a substantial market potential, primarily in single-use applications where existing plastic products tend to become soiled and therefore difficult to recycle or recover.
Monsanto are actively interested in pursuing other people who may be interested in continuing the research and development. They exited this business for corporate rather than product-related reasons, but still believe in Biopol® as a product. It is anticipated the Biopol® will be sold as a complete unit to an organisation interested in developing it to an economically viable product.
Associated
Biopol® has been shown to be suitable for use in biocomposites. For example, Warwick Manufacturing Group has devised a process to impregnate thick natural fibre felts (typically 450 gsm) with viscous Biopol® melts. In a two-stage extrusion compression process, a Dassett compression extruder was loaded with Biopol® and 15 w% chopped Miscanthus fibre. Layers of fibre were placed in a mould and the filled matrix extruded onto it. Further layers of reinforcement were then added and the mould closed to consolidate the product. This method proved successful in manufacturing plaques with up to 8 layers of 450 gsm hemp felt, and is now the subject of a patent application.
Contacts
Author
Monsanto Co
University of Coventry
© Copyright 2006 Policy Statements
Updated
by CPL Press:
03/07/2007
- biomatnet@biomatnet.org
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