Biobased plastics are reshaping the future of materials offering lower carbon footprints, compatibility with existing systems, and, in the case of PHA, true biodegradability.
The biopharma industry stands at a pivotal moment in its evolution. As the demand for biologics and personalized medicines continues to rise, so too does the reliance on single-use technologies (SUTs). These systems—including filtration units, bioprocess bags, tubing, and connectors— have become indispensable to modern manufacturing. They offer flexibility, reduce the risk of cross-contamination, and eliminate the need for resource-intensive cleaning processes. Yet, their widespread adoption has introduced a new challenge: the environmental burden of plastic production and waste.
A promising alternative is emerging: biobased plastics. These materials, derived from renewable sources such as corn starch, cellulose, and waste oils, offer a pathway to reduce the environmental impact of SUTs without compromising performance. As sustainability becomes a strategic imperative, biobased plastics have potential to be a viable solution that supports both operational goals and environmental responsibilities.
The shift toward biobased materials is not occurring in a vacuum. External regulatory, economic, and societal forces are amplifying the push toward biobased materials. Governments across Europe and North America are tightening regulations on plastic waste, while investors and consumers are demanding greater transparency and accountability in corporate sustainability practices. Sciencebased emission targets are now the norm in biopharma, and raw materials—especially plastics—are among the largest contributors for most companies. In this context, adopting biobased plastics is more than environmental stewardship, it’s a strategic business decision.
Advancements in PE and PP
As industries seek to reduce their environmental footprint, biobased plastics offer a practical alternative to fossil fuelderived materials. Among these, biobased polyethylene (PE) and biobased polypropylene (PP) stand out for their ability to integrate seamlessly into existing manufacturing and recycling systems while delivering meaningful sustainability benefits.
Biobased PE and PP are chemically and mechanically identical to their conventional counterparts, allowing them to be processed with the same equipment and recycled within current infrastructure. This compatibility makes them an attractive drop-in solution for companies aiming to reduce carbon emissions without disrupting operations. Derived from renewable feedstocks these materials offer a significantly lower carbon footprint across their lifecycle.
Despite their renewable origins, biobased polyolefins are ready to meet the demands of biopharma applications. In filtration units, for example, biobased polymers can be used for housings that maintain structural integrity under pressure and gamma irradiation. They can offer the same solvent resistance and dimensional stability as conventional materials, ensuring critical filtration processes remain uncompromised. In single-use bags and tubing, multilayer films incorporating biobased components can deliver the barrier properties needed to protect sensitive biologics from oxygen and moisture, while withstanding freezing, thawing, and agitation—routine stressors in biopharma workflows.
Beyond emissions reduction, biobased polyolefins support the transition to a circular economy by shifting plastic production away from fossil resources. This transition lowers the environmental impact of plastic production and creates new demand for waste feedstocks—organic by-products and residues that currently hold little or no economic value. By turning waste into raw material, biobased polyolefins incentivize recovery and reuse, fostering circular business models that link waste streams to raw material production and reinforcing resource efficiency.
At Cytiva, we’re proud to begin using bio-based polymers in our products. Starting this year, several of our lab filtration products will feature biobased PP, delivering measurable reductions in carbon footprint. While the impact per product may be modest, the cumulative effect across typical annual use is significant—supporting meaningful reductions in our customers’ Scope 3 emissions. Cytiva is also working to expand the use of biobased polymers across more singleuse products later this year. All claims will be backed by ISCC certification across our relevant manufacturing sites and supply chain partners, ensuring transparency and credibility in our sustainability efforts.
Considerations for biobased plastics
Any new material introduced into a biopharmaceutical process must undergo rigorous testing to ensure it doesn’t compromise product safety or efficacy. However, because biobased PE and PP are chemically identical to conventional materials, they can be used as ‘drop-in’ replacements, eliminating the need for additional validation or testing.
Cost is another key consideration. While prices of biobased plastics have declined in recent years due to advances in production methods and economies of scale, they still tend to be higher than conventional polymers. However, this premium must be weighed against long-term benefits— particularly the potential to reduce Scope 3 emissions, a vital yet challenging component of most companies’ carbon reduction goals and profit.
Supply chain stability is also critical. Biopharma manufacturers require consistent, high-quality materials at scale, which often calls for close collaboration across the value chain. Joint development programs, long-term supply agreements, and shared sustainability goals can help de-risk the transition and accelerate innovation.
Suppliers play a crucial role in this shift. Investment in research and development is essential to tailor biobased formulations for biopharma applications. They should also provide transparent lifecycle data, including carbon footprint and recyclability assessments, to support informed decision-making. In addition, suppliers can play a key role in developing take-back programs and closed-loop recycling systems that further enhance the sustainability of single-use technologies.
PHA: Unlocking the power of biodegradability
While biobased PE and PP offer carbon savings and compatibility, polyhydroxyalkanoates (PHA) represent a different kind of innovation—one rooted in end-of-life solutions. PHAs are a family of biopolymers produced by microbial fermentation of renewable resources. A wide range of feedstocks can be used to produce PHA, including plant-based feedstocks, biomass waste streams, and even greenhouse gases including carbon dioxide and methane.
Unlike traditional plastics, PHAs are fully biodegradable in compost, soil, and marine environments, and eliminate the risk of forming persistent microplastics. This makes PHA particularly relevant for applications where plastic waste is difficult to collect or recycle due to contamination, such as single-use products.
Its ability to break down naturally addresses the growing concern over plastic pollution, especially in ecosystems where conventional plastics persist for centuries.
PHA’s environmental benefits are backed by rigorous testing and real-world validation. In the right environment, they rapidly degrade into carbon dioxide and water without leaving behind toxic residues, making them a powerful tool in the fight against plastic pollution. PHAs can also be recycled into new applications, further enhancing their sustainability profile.
Beyond biodegradability, PHAs are also biocompatible, opening doors for medical and pharmaceutical uses such as drug delivery systems. As production technologies improve and costs decrease, PHAs are gaining traction as a versatile material that may complement the broader portfolio of sustainable plastics.
Despite their promise, PHAs currently face challenges related to cost, scalability, and processing performance. Production remains notably more expensive than conventional plastics, and processing PHAs often require specialized equipment adjustments. However, advances in microbial engineering, feedstock optimization, and fermentation efficiency promise to improve the economic viability of PHAs for pharma and medical applications.
As regulatory pressure intensifies and demand for sustainable materials grows, PHAs are poised to play a critical role in the next generation of bioplastics. With tunable material properties and performance characteristics similar to polypropylene, PHAs are well-positioned to support the sustainable transformation of bioprocessing. Biobased, biocompatible, and biodegradable, PHAs offer a promising path to truly sustainable materials capable of meeting performance demands of future pharma applications.
A strategic shift toward sustainability
In summary, biobased PE and PP offer a low-carbon, infrastructure-friendly solution for mainstream plastic applications, while PHA holds promise as a future, longerterm solution—combining non-fossil based production with improved end-of-life options, including biodegradation and elimination of microplastics. Together, these materials form a powerful toolkit for advancing sustainability in plastics through both emissions reduction and end-of-life outcomes.
Ultimately, the transition to biobased plastics is more than a material swap. It represents a broader shift in how the biopharma industry approaches innovation, responsibility, and resilience. By embracing renewable materials, companies can reduce their environmental impact, meet stakeholder expectations, and position themselves as leaders in sustainable healthcare manufacturing.
As the biopharmaceutical sector continues to grow and evolve, the choices made today will shape its legacy for decades to come. Biobased plastics offer a tangible, impactful way to align operational excellence with environmental responsibility.
The time to act is now.
