8 Plastic-Killing Materials to Know About in Fall 2024

For the world to break up with plastic, better alternatives with less environmental impact must be identified and industrialized. Luckily for us, there are a lot of smart people out there working on developing and scaling some incredibly interesting technologies and alternatives. Here are 8 of the most compelling up-and-coming plastic alternatives in development as of Fall 2024.

Polylactic Acid (PLA), or starch-based plastic, is a bioplastic made from fermented plant starch like corn, potato, or sugarcane. PLA is compostable under industrial conditions and can replace polyethylene terephthalate (PET), polypropylene (PP), and acrylonitrile butadiene styrene (ABS). Applications include packaging boxes, disposable tableware, and cosmetic packaging. Key companies developing this technology include NatureWorks, Futerro SA, Luminy PLA (TotalEnergies Corbion), Novamont, Plantic Technologies, and BioLogiQ. Advantages include derivation from renewable resources, lower carbon footprint than traditional plastic, versatility comparable to petroleum-based options, food safety credentials with no phthalates, and compostability within three to six months. However, PLA is less durable than conventional plastic, requires specific industrial composting conditions unsuitable for home use, and many countries lack proper composting infrastructure, leading waste to incinerators. Additionally, PLA can be confused with PET during recycling, potentially compromising operations, and its production competes with food crops for agricultural land.

Bacterial cellulose consists of ultrafine cellulose nanofiber threads produced by bacteria and spun into plastic alternatives. This material suits food packaging, coatings, and films. Materic Group and the Chinese University of Hong Kong are developing this technology. Bacterial cellulose biodegrades rapidly in one to two months and is compostable, strong, flexible, and safe to consume with non-toxic properties. It can be cultivated using waste materials as feedstock and demonstrates superior water-holding capacity and tensile strength compared to plant-based cellulose. The material remains expensive and difficult to scale for large production, has limited current applications due to production constraints, and is still in early development phases for many uses.

Seaweed and algae-based materials are processed from seaweed or algae into films, coatings, and packaging that decompose naturally and can sometimes be eaten. Applications encompass edible packaging, flexible films, polybags, utensils, food wraps, and laundry sachets. Companies like Notpla, Bzeos, Sway, Loliware, and Evoware are pioneering this space. Seaweed and algae grow rapidly without requiring fresh water or fertilizers, represent highly sustainable and abundant resources, biodegrade and compost in natural environments, and some formulations offer zero-waste solutions through edibility. Limited supply chains, higher production costs, narrower versatility compared to conventional plastics, and potential shelf-life and durability issues in certain applications present challenges.

Chitosan, derived from chitin, is manufactured from crustacean shells and fish scales. Chitosan-based materials possess antimicrobial properties suitable for food packaging, medical dressings, and films. MarinaTex and CuanTec are developing these applications. These materials biodegrade and compost naturally while providing natural antimicrobial benefits for food preservation and utilizing waste byproducts from seafood industries. Scalability limitations due to source material availability, unsuitability for large-scale applications like traditional plastics, and potential shellfish allergen concerns restrict deployment.

Polyhydroxyalkanoates (PHA) are biopolymers produced through bacterial fermentation of organic matter. PHA biodegrades in various environments including ocean settings within three months. Applications include packaging, utensils, single-use items, and laminations. RWDC Industries, Danimer Scientific, and Genecis Bioindustries are developing this technology. PHA fully biodegrades across multiple environments, derives from renewable sources like organic waste, and accommodates diverse applications. High production costs relative to conventional plastics, early commercialization stages, and inferior thermal and mechanical properties present obstacles.

Molded fiber or molded pulp is created from recycled paper or natural fibers. Molded fiber products decompose naturally and can supplant styrofoam. Applications include food containers, trays, and protective packaging. Companies like Molded Fiber Technology, Sustainable Packaging Industries, Single Use Alternatives, and Footprint develop these solutions. These products utilize readily available recycled materials, compost easily at home and industrial facilities, eliminate petroleum requirements, avoid forever chemicals, and maintain shelf stability. Applications are limited where water resistance proves critical, durability may suffer in certain scenarios, moisture-resistant coatings can compromise compostability, and non-recycled fiber sources may drive deforestation increases.

Liquid wood, also known as Arboform, is a bioplastic derived from lignin, a paper industry byproduct. It can be molded like plastic while remaining biodegradable. Applications suit office supplies, household items, and packaging. Tecnaro specializes in this technology. Liquid wood utilizes waste materials, reduces environmental footprints, performs in molded plastic applications, and biodegrades under appropriate conditions. Limited production capacity, unsuitability for flexible or transparent applications, and heavier, more brittle, costlier characteristics than conventional plastics limit adoption.

Mycelium, or mushroom-based materials, are manufactured from mushroom root structures. Mycelium grows into compostable packaging materials for packaging and insulation applications. Companies including Mushroom Packaging by Ecovative and Grown Bio develop these solutions. Mycelium products completely compost, grow from renewable resources, can be customized for different properties and uses, resist flames and chemicals, provide water resistance, and remain carbon-neutral. Production remains difficult to scale, growth requires time unsuitable for flexible film production, and manufacturing costs exceed mass-produced plastics significantly.

While these eight alternatives remain far from achieving the scale necessary to replace petroleum-based polymers, numerous breakthroughs are occurring that advance progress toward a more sustainable future.