Biomaterials in Manufacturing: A Sustainable Shift Away From Plastics

Manufacturers face growing pressure. Consumers demand eco-friendly products. Biomaterials offer a real solution. They can replace traditional plastics. This blog explores how.

Why Biomaterials are Gaining Traction

Traditional plastics pose problems. They come from fossil fuels. They pollute our environment. Biomaterials offer a greener choice. They are often made from renewable resources. They can also be biodegradable, but not always: “bio-based” and “biodegradable” are separate properties. European Bioplastics defines bioplastics as plastics that are biobased, biodegradable, or both.

Market Snapshot: Capacity, Utilisation and Packaging

The numbers show a young but growing industry. European Bioplastics and the nova-Institute put global bioplastics production capacity at 2.47 million tonnes in 2024, forecast to reach 5.73 million tonnes in 2029. Packaging is the largest segment, at 45% (1.12 million tonnes) of the 2024 market, while automotive and transport accounted for about 206,000 tonnes.

Capacity is not the same as output. In 2024, production ran at about 58% of capacity (down from 68% in 2023), so the constraint today is as much demand and economics as it is plant availability. By material, PLA made up 37.1% of 2024 capacity and PHA 4.1%, with PHA forecast to reach 17.0% of capacity by 2029.

The Benefits of Using Biomaterials in Products

What are the advantages? Less reliance on fossil fuels. A potentially lower carbon footprint, depending on the feedstock, process and end-of-life route, so ask suppliers for a life-cycle assessment rather than relying on a general claim. Improved brand image. Meeting consumer demand for sustainable goods are a few.

Some suppliers publish their own figures. TotalEnergies Corbion, for example, says its Luminy PLA made from Thai sugarcane has an 85% lower carbon footprint than conventional plastics (company-reported). Treat vendor numbers like this as a starting point for your own assessment.

Types of Biomaterials Manufacturing

Several types of biomaterials exist. Plant-based plastics like PLA are the largest by capacity (37.1% of 2024 bioplastics capacity, per European Bioplastics). Others include PHAs, starch-containing compounds, bacterial cellulose and fungal materials. Each has unique properties. Each suits different applications.

Consider starch-containing polymer compounds, which made up 5.7% of 2024 capacity in the same data. Algae-based materials are also emerging, though we found no reliable capacity figures for them.

Bio-based vs. Biodegradable: What to Specify

Before you choose a material, decide what you need. “Bio-based” describes the raw material. “Biodegradable” or “compostable” describes what happens at end of life, and conditions matter. PLA, for instance, is described as compostable only under industrial composting conditions (sustained temperatures of at least 58°C), and generally not suitable for home compost. The standards that define industrial compostability are ASTM D6400 and EN 13432. Ask suppliers which certification a specific grade holds. BASF’s ecovio, for example, lists EN 13432 for most grades and a home-composting certification for only one named grade.

Industrial Scale Production of Biodegradable Polymers

Scaling up production is key. Can we make enough biomaterials? Capacity is expanding: European Bioplastics expects it to more than double from 2.47 to 5.73 million tonnes by 2029. Efficiency and cost remain the focus of manufacturers and researchers.

Investment in infrastructure is vital. NatureWorks, for example, opened a PLA plant in Thailand in 2026 with a stated capacity of about 75,000 tonnes a year, using locally sourced sugarcane. Plants like this must run at high utilisation to be efficient, which ties back to demand.

Biomaterials Replacing Plastics Manufacturing

How do we switch to biomaterials? It requires careful planning. Companies must assess their needs. They must choose the right biomaterials. They must adapt their manufacturing processes.

Collaboration is important. Manufacturers should work with biomaterial suppliers. They should also partner with research institutions. This helps smooth the transition.

Manufacturing Processes for Biomaterials

The process depends on the material. Some biomaterials require fermentation. Others need chemical modification. Understanding these processes is crucial.

Producers such as NatureWorks (PLA) and Novamont (biodegradable and compostable bioplastics, now fully owned by Versalis, Eni’s chemicals company) operate at industrial scale. Mitsubishi Chemical’s BioPBS is made by a Thai joint venture, PTT MCC Biochem.

Applications of Biomaterials in Automotive Industry

The automotive sector is exploring biomaterials. They can be used in interior parts. They can also replace certain plastic components. Automotive and transport is still a small outlet, at about 206,000 tonnes of bioplastics in 2024, so there is room to grow.

Companies are testing bio-based composites as a lighter, more sustainable alternative to conventional materials. Weight and strength vary by material and part, so request test data from the supplier. For the high-performance end of the field, see our overview of advanced composites manufacturing techniques.

Sustainable Packaging Solutions Manufacturers

Packaging is a major area of focus. Single-use plastics are a huge problem. Biomaterials offer a solution. They can create compostable packaging, and packaging is already the largest bioplastics segment at 45% of the 2024 market.

Look at companies like Novamont, a benefit company focused on biodegradable and compostable bioplastics. Whether a compostable film actually reduces waste depends on whether it reaches an industrial composting facility, so match the material to the local collection system.

Cost of Biomaterials vs Plastics

Cost is a major factor, and it varies by material, grade and volume. We could not find a reliable, current price comparison to publish here, so get quotes for your specific application and volume instead of relying on a rule of thumb.

Consider the full picture: raw material price, processing changes, certification, and what happens at end of life.

Suppliers of Biomaterials for Industry

Finding reliable suppliers is essential. Several companies specialize in biomaterials. Look for suppliers that offer high-quality materials. They should also provide technical support.

Some key suppliers include BASF (ecovio, a compound of its compostable ecoflex polymer and PLA), TotalEnergies Corbion (Luminy PLA made from sugarcane) and Mitsubishi Chemical (BioPBS, a bio-based biodegradable polymer). Their portfolios cover different industries and applications.

Research and Development in Biomaterials

R&D is crucial for progress. Researchers and suppliers are working on new biomaterials and on improving existing ones, with the aim of better performance and lower costs. Which advances reach commercial scale is still uncertain.

Impact on Key Sectors

Several sectors are affected by this shift:

• Materials Science Companies: Opportunity to innovate and develop new biomaterials.
• Chemical Companies in the US: Potential to shift production towards bio-based chemicals.
• Packaging Companies in the US: Chance to offer sustainable packaging solutions.
• Materials & Chemicals, Packaging Industry, Manufacturing Companies (adopters) in India: Can adopt biomaterials for local production and export.

Conclusion: The Future is Biomaterials

Biomaterials offer a promising alternative to traditional plastics, but the details matter: bio-based is not automatically biodegradable, and compostable is not automatically home-compostable. With capacity forecast to more than double by 2029, wider adoption is plausible, but it depends on demand, cost and end-of-life infrastructure.

The transition requires collaboration, innovation, and a commitment to sustainability. By embracing biomaterials, manufacturers can create a more environmentally friendly future.