The new, sustainably produced plastic material is cost-effective and biorenewable. (Credit: Cockrell School of Engineering)

A team of chemical engineers has developed a new, cost-effective method for synthetically producing a biorenewable platform chemical called triacetic acid lactone (TAL) that can be used to produce innovative new drugs and sustainable plastics at an industrial scale.

The team's new method involves engineering the yeast Y. lipolytica to increase production of TAL, a polyketide, to levels that far exceed current bioproduction methods. This was accomplished by rewiring metabolism in the yeast through synthetic biology and genetic engineering. Ultimately, the research team increased production capacity tenfold, enabling polyketides to be mass-produced for incorporation into a variety of new applications in industry.

Up to this point, synthetic production of polyketides has been constrained by technical challenges, limiting practical applications for consumer- and industry-based needs. In particular, most technologies have limited product yields resulting in difficult chemical synthesis and poor economics. The team's breakthrough could change that.

Using their new method, the researchers were able to purify TAL directly from a bioreactor to make a new plastic material that can be formed into a film and is seen to exhibit an orange hue and relative transparency.

The researchers have filed U.S. patent applications for the technology and is working to secure worldwide patents. The office is seeking commercial partners who have interest in improving the economics of polyketide production or creating new materials or products from polyketides.

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