Irish journalist here, bringing you a unique and accurate take on a groundbreaking innovation in the fight against greenhouse gas emissions.
What if the world could harness methane, a potent greenhouse gas produced by industries like agriculture and wastewater treatment, and convert it into a valuable resource? That’s precisely the vision of Mango Materials, a biomanufacturing company based in California.
Mango Materials is pioneering a process that utilizes methane-eating microorganisms to convert methane emissions into polyhydroxyalkanoate (PHA), a biodegradable polymer. This innovative polymer is then used to produce 100% biodegradable polyester pellets, which can be fashioned into durable goods, fabrics, and flexible films.
Unlike traditional plastics, products made from PHA decompose at a much faster rate—within weeks or months. Furthermore, when disposed of properly, these materials revert back into methane and carbon dioxide. Allison Pieja, co-founder and Chief Technology Officer of Mango Materials, highlights the significant environmental benefits of their technology, stating, “Our analyses indicate that it should have a carbon-negative impact when operating at full capacity.”
Mango Materials recently completed the construction of a PHA production facility at a wastewater treatment plant in Vacaville, California. Here, they capture methane produced by microbes involved in purifying the public water supply and introduce it into bioreactors containing their methane-consuming bacteria.
The bacteria convert methane into chains of PHA to store energy, a process akin to how plants store energy in starches through carbon dioxide-based sugars. These PHA molecules accumulate within the bacterial cells for future use. The company has already begun producing sufficient amounts of PHA for demonstration products, such as a soap dish, net-zero sneakers in collaboration with Allbirds, and sustainable sunglasses designed by Stella McCartney. Mango Materials is aiming to scale up production to supply PHA pellets for a wide range of eco-friendly products.
CEO and co-founder Molly Morse sees a substantial market opportunity for bio-based plastics that offer the same biodegradability as PHA, combined with its mechanical properties.
The transition from laboratory-scale research to a commercial process was a gradual one for Mango Materials. The Advanced Biofuels and Bioproducts Process Development Unit (ABPDU) at Lawrence Berkeley National Laboratory played a pivotal role in this transition. Supported by the U.S. Department of Energy’s Bioenergy Technologies Office, ABPDU specializes in upscaling bio-based technologies.
Since its establishment in 2012, Mango’s team collaborated with ABPDU to optimize their bacterial culture and the conditions for achieving high yields of PHA. Led by Ning Sun, ABPDU tested industrial-scale equipment alongside Mango scientists to improve the extraction of PHA from microbial broth. Sun emphasized the various scales at which they received broth from Mango, testing different recovery unit operations to enhance yield and purity.
This collaboration culminated in a successful process that Mango Materials believes will be financially viable. Access to downstream processing facilities and expertise was crucial for the biomanufacturing company.
Furthermore, the ABPDU team gained valuable insights into the extraction of intracellular biopolymers. To date, ABPDU has aided 85 industry partners and 20 national laboratories in scaling up innovative biology-based products. Mango Materials’ endeavors were supported by grants from the Department of Energy, with ABPDU playing a vital role in the advancement of sustainable technologies.
Mango Materials’ innovative approach of utilizing bacteria to convert methane into biodegradable PHA presents a promising solution to the challenges of plastic waste and greenhouse gas emissions. As this technology is scaled for broader impact, excitement abounds for the potential positive effects it could have on our environment.
This is a remarkable step forward in the ongoing battle against climate change, showcasing the power of innovation and collaboration in addressing pressing environmental issues. Let’s hope that initiatives like Mango Materials serve as inspiration for further advancements in sustainable technologies worldwide.
