BIO-BASED PLASTICS: THE PACKAGING INDUSTRY IS SEEKING ALTERNATIVES TO OIL
In the packaging sector, this dependence creates a dual challenge: economic and environmental. Conventional plastics are derived from oil or gas—two resources whose prices remain highly volatile and whose carbon footprint is significant.
In this context, bio-based plastics are attracting growing interest. Produced from renewable resources such as corn, sugarcane, cellulose or plant fibres, they make it possible to reduce dependence on fossil materials while maintaining the technical properties required for packaging production.
This transition is still gradual, but industrial signals are multiplying.
Today, the global bioplastics market is estimated at more than $23 billion and could exceed $119 billion by 2035, with annual growth approaching 17%.
Within this momentum, packaging already represents the largest application market, accounting for more than 41% of global bioplastics volumes.
Materials derived from living resources
The term “bio-based plastic” refers to a material whose raw material is partially or entirely derived from renewable resources.
Among the polymers most commonly used in packaging today are:
- PLA (polylactic acid) produced from corn or beet starch
- Bio-PE, manufactured from ethanol derived from sugarcane
- Plastic composites incorporating natural fibres such as wood or flax
These materials can be used to manufacture a wide variety of packaging formats, including bottles, caps, films, trays and technical components. However, they still represent a very small share of the overall plastics market. Bioplastics currently account for only around 1% of global plastic production, which amounts to several hundred million tonnes each year. The growth potential therefore remains considerable.
Manuplast: an example of industrial experimentation
Beyond the rhetoric, several plastics manufacturers are already experimenting with these new materials.
One example is Manuplast, a French company founded in 1957, specialising in the production of technical plastic components through injection moulding and extrusion blow moulding.
The company supports its industrial clients in developing solutions that integrate more sustainable materials. Among the avenues currently being tested are:
- the use of bio-based PLA
- plastics reinforced with natural fibres such as wood or flax
- polymers derived from sugarcane
These trials are carried out in collaboration with material manufacturers to verify the compatibility of these materials with existing industrial processes. The challenge is crucial: in the packaging industry, a new material can only be adopted if it integrates seamlessly into existing production lines. At Manuplast, testing therefore focuses both on mechanical performance and on the ability of bio-based materials to be processed using industrial techniques such as plastic injection moulding and extrusion blow moulding.
Another example of an industrial approach concerns production residues—known in plastics manufacturing as “sprues”. These can be ground down and reintroduced into the production of new parts, sometimes up to 100% depending on specifications, thereby contributing to a circular economy logic.
Innovation driven by the entire packaging value chain
The transition towards bio-based plastics does not concern plastics processors alone.
It involves the entire packaging value chain, including:
- polymer producers
- packaging manufacturers
- brands and retailers
- research centres
Several major material producers, such as NatureWorks and TotalEnergies Corbion, are investing heavily in the production of biopolymers. At the same time, numerous startups are developing new generations of plastics derived from still under-exploited resources such as algae, agricultural waste and food residues.
These innovations are part of a broader transformation of the packaging industry, where the search for more sustainable materials is becoming a key factor of competitiveness.
Challenges to overcome for large-scale adoption
Despite their potential, bio-based plastics must still overcome several obstacles before they can be adopted on a large scale.
The first challenge remains production costs. Biopolymers are generally more expensive than petrochemical plastics, whose supply chains have been optimised for decades.
The second challenge concerns technical performance. Manufacturers must ensure that these materials provide:
- the same mechanical strength
- the same thermal stability
- the same compatibility with production lines
Finally, end-of-life management remains a central issue. Not all bio-based plastics are biodegradable, and their recyclability largely depends on existing recycling infrastructures.
For the industry, the objective is therefore to develop materials capable of integrating into current recycling systems.
A gradual but inevitable transformation
The transition towards more sustainable materials in packaging will not happen overnight. However, economic, regulatory and environmental developments are accelerating the search for alternatives.
Bio-based plastics now represent one of the most promising avenues for reducing dependence on fossil resources. Industrial initiatives, such as those undertaken by Manuplast and other plastics manufacturers, demonstrate that innovation is already underway.
For packaging professionals, the challenge is no longer simply to observe these developments, but to test, experiment with and progressively integrate these new materials into production chains.
Because in a context of energy transition and increasing environmental pressure, the materials of tomorrow are being designed today.