PRACTICAL MANUFACTURING OF BIOPLASTICS FROM ALGAE

The use of algae to reduce the environmental carbon load is gaining increased attention. Algae have a high efficiency in capturing CO2 as bicarbonate in ponds, reducing atmospheric CO2 emissions. This also reduces competition for land, particularly arable land, used for food production. Algae are estimated to produce 2-10 times more biomass per unit land area than any other type of approach used on land. Algae are more efficient in their photosynthetic capture of light energy than land plants. Under ideal conditions, they direct most of their energy into cell division, allowing for rapid biomass accumulation. With algae, all the biomass can be harvested at any time of the year, rather than seasonally. Importantly, production systems for algae can be tightly controlled and optimized. Temperature, pH, and nutrient and CO2 concentrations can be monitored and optimized for maximum biomass production. Algae are relatively easy to grow in artificial ponds, harvested, and processed for biomass utilization.

 The use of algae-derived biomass for production of biofuels has been considered and evaluated. However, the use of algae to produce bioplastics with the appropriate characteristics to be credible replacement for petroleum-based plastics has not been extensively evaluated. Algae biomass has been used as fillers and additives in producing more environmentally friendly plastic alternatives. However, bioplastics derived predominantly from algae biomass have not been produced yet because the resulting strength, plasticity, and moldability do not favorably compare to standard plastic containers. 

At Ingenuitas, we are exploring the potential use of algae biomass in the production of sustainable bioplastics that have comparable structural and manufacturing capabilities to current plastics. This can be accomplished by chemical crosslinking of algae structural proteins. Ingenuitas is investigating different crosslinking agents and optimal formulations to generate the best bioplastic from algae protein. The test case to evaluate different formulations is to develop 3D print filament. This is a practical and effective model system to evaluate formulations. The resulting filament can be used to print shapes that can be assessed for a battery of characteristics, such as the ability to be molded, strength, water resistance, potential for composting, and temperature sensitivity, among others. 

The search for answers to the plastics crisis is an important endeavor.  At Ingenuitas we believe that a solution based on algae both addresses global warming, through the capture of environmental CO2, and a viable alternative to current plastic chemicals. Algae-based products could be compostable or be able to be efficiently processed using enzymatic degradation. If successful, this program could provide an important alternative to address the global waste and climate crisis we are facing.