Polyhydroxyalkanoates for sustainable food packaging: A comprehensive review on production, applications, and end-of-life scenarios for food packaging

Abstract

Background

The growing environmental impact of petroleum-based plastics has accelerated the demand for biodegradable alternatives in food packaging. Polyhydroxyalkanoates (PHAs), a diverse class of microbial polyesters derived from renewable feedstocks, have attracted increasing attention due to their biodegradability, compostability, and compatibility with bio-based additives. However, limitations in material properties and high production costs have hindered their widespread commercial adoption.

Scope and approach

This review provides a comprehensive overview of the recent status and progress in the development of PHAs for food packaging applications. It critically evaluates material optimization strategies, copolymerization, blending, plasticization, and multilayer structuring, aimed at overcoming inherent limitations such as brittleness and narrow thermal processability. Additionally, the integration of active and smart functionalities is examined, particularly those employing edible and bio-based antimicrobial, antioxidant, and sensing agents. The review further addresses environmental fate by summarizing biodegradation performance under various disposal scenarios, including industrial composting, soil, marine, and anaerobic conditions. Commercialization trends and approved food-contact resins are also discussed.

Key findings and conclusions

Material engineering approaches have significantly improved the flexibility and functionality of PHA-based films, enabling their use in both passive and active packaging formats. While biodegradation remains the main end-of-life route, harmonized assessment protocols are needed to reflect real-world conditions. Regulatory inconsistencies and limited recycling infrastructure further hinder market expansion. To accelerate adoption, future research should focus on developing robust PHA materials, standardized biodegradability testing, application-oriented product design, and international regulatory alignment. These efforts will facilitate the transition of PHAs from niche biomaterials to mainstream sustainable packaging solutions.