Scientists in South Korea have developed a new biotechnology that uses engineered microbes to turn biodiesel waste into an important ingredient used in plastics, textiles, and cosmetics.
The breakthrough could help reduce dependence on petroleum-based chemicals while also recycling industrial waste that would otherwise be discarded.
The research was led by scientists at KAIST in collaboration with Hanwha Solutions. Their findings were published in the journal Nature Chemical Engineering.
Modern petrochemical industries rely heavily on naphtha, a petroleum-derived raw material used to produce plastics, synthetic fibers, and many other everyday products.
However, rising prices and unstable supplies have increased interest in finding cleaner and more reliable alternatives.
The new technology focuses on glycerol, a waste byproduct created during biodiesel production.
Large amounts of glycerol are generated worldwide, and much of it has limited economic value. Instead of treating it as waste, the researchers designed microorganisms that can convert glycerol into a valuable chemical called 1,3-propanediol, or 1,3-PDO.
This chemical is widely used in products such as plastics, cosmetics, coatings, and textile materials.
To make the process work efficiently, the scientists genetically engineered microbes to produce higher amounts of 1,3-PDO. They also used computer simulations to predict which genes should be modified to improve production performance.
One of the biggest achievements of the study was successfully scaling the process beyond the laboratory. The team demonstrated stable production in a 300-liter pilot fermentation system, an important step toward future industrial manufacturing.
Scaling up biotechnology from small lab experiments to large industrial systems is often extremely difficult because microorganisms may behave differently under large-scale production conditions.
Maintaining strong performance at the 300-liter level suggests the technology could eventually be used in commercial manufacturing plants.
The researchers also removed the need for antibiotics during the fermentation process. In many industrial microbial systems, antibiotics are used to maintain genetic stability, but their use can create concerns about antimicrobial resistance and regulatory approval, especially for products connected to food, cosmetics, or health industries.
Avoiding antibiotics makes the process safer and potentially easier to commercialize.
The project reflects a decade-long collaboration between KAIST and Hanwha Solutions that began in 2015. Over the years, the partnership has produced multiple scientific papers and patent applications, becoming an example of successful cooperation between universities and industry in South Korea.
Researchers say the work demonstrates that microorganism-based chemical production can move beyond laboratory experiments and become a realistic industrial solution.
The technology could help create a more sustainable chemical industry by reducing reliance on fossil fuels, lowering waste, and producing materials in a more environmentally friendly way. Scientists also believe similar approaches could eventually be used to manufacture many other chemicals and materials currently made from petroleum.
As industries search for greener production methods, engineered microbes may play an increasingly important role in transforming waste into valuable resources.
