Microbial protein-derived bioplastics from renewable substrates: pathways, challenges, and applications in a circular...

Microbial protein (MP)-the protein-rich biomass derived from recovered or virgin resources-is attracting interest as a source of food and feed. However, its potential as a feedstock for protein-based bioplastics remains underexplored. Proteins offer desirable properties, including superior oxygen-barrier capabilities and complete biodegradability, making them ideal for applications from food packaging to agricultural mulches. Currently, most protein-based bioplastics derive from crops such as wheat, restricting applications and competing with food production. MP can overcome these limitations by supplying diverse proteins from various inputs, including CO₂, biomass, and liquid side-streams. In this review, we evaluate bioprocessing pathways for producing MP from renewable and waste-derived substrates from an interdisciplinary viewpoint. We also examine the technical, regulatory, market, and environmental factors to address, delineating the pathway from substrate to MP-based plastics and highlighting key challenges throughout the production chain. Novel strategies-such as efficient co-recovery of proteins with other cellular products like polyhydroxyalkanoates or direct use of microbial biomass without extraction-are essential to maximize environmental and economic sustainability. Carefully chosen processing methods for recovered proteins, including wet and dry blending or extrusion with other biopolymers, can yield diverse products. Concurrently, policy and market developments are vital for adopting MP-based bioplastics. Addressing these challenges will enable MP-based bioplastics to propel the shift toward a circular economy, diminishing dependence on fossil-derived plastics and alleviating plastic pollution.