One-step polyhydroxybutyrate production from potato starch by engineered Bacillus subtilis

Bacillus subtilis is widely used as an industrial workhorse for enzymes and chemical commodity production, yet its potential for polyhydroxybutyrate (PHB) production has remained largely untapped, with previous reports showing only modest polymer accumulation below 13 % of dry cell weight (DCW). Here, B. subtilis has been engineered for high-level PHB biosynthesis via PHB pathway optimization and phasin expression, achieving 47.3-54.9 % DCW from diverse carbon sources. Expression of α-amylase (amyQ) enabled direct, one-step PHB accumulation from minimally processed potato starch, reaching 51.8 % PHB of DCW, with a titer of 5.8  g/L and biomass of 11.3  g/L under optimized 3 % starch conditions. Polymer characterization confirmed PHB identity, with molecular weight distribution, thermal behavior, and purity comparable to commercial standards. This work establishes B. subtilis as a Gram-positive platform for efficient, sustainable PHB production from unprocessed starch, highlighting its potential for cost-effective bioplastic manufacturing.