'Microbes instead of oil': KAIST team maps path to commercializing biomanufacturing

South Korean researchers have identified the core obstacles blocking the commercialization of biomanufacturing — a process that uses microbes instead of petroleum — and proposed an AI-driven industrialization strategy to overcome them.

KAIST said Tuesday that a research team led by Distinguished Professor Lee Sang-yup of the Department of Biological and Chemical Engineering conducted a comprehensive analysis of the key bottlenecks hindering biomanufacturing commercialization and laid out an industrialization roadmap and future development directions.

Most chemical products — including plastics, textiles and pharmaceutical ingredients — are derived from petroleum. As concerns over carbon emissions and environmental pollution grow, biomanufacturing, which uses microorganisms to produce chemical substances, is drawing attention as a next-generation manufacturing technology. Scaling laboratory-developed processes into economically viable mass production at actual factories remains a major challenge.

The research team examined succinic acid, a bio-based chemical feedstock, and polyhydroxyalkanoate (PHA), a biodegradable plastic, as representative cases illustrating what researchers call the "Death Valley" gap between laboratory research and industrial application.

Succinic acid is a key raw material for eco-friendly plastics and a range of chemical products. To compete with conventional petrochemical products, the team said, factors beyond output must be addressed — including feedstock prices, fermentation processes, separation and purification costs, and market size. The team proposed using low-cost raw materials, cutting costs through process integration such as low-pH fermentation that reduces neutralizing agents and membrane-based electrochemical separation, and targeting high-value specialty markets — such as high-purity products for pharmaceutical, cosmetics and food applications — before competing on price in commodity markets.

PHA is a biodegradable plastic that microorganisms accumulate inside their cells and that breaks down naturally after use. High production and recovery costs leave it at a price disadvantage against conventional plastics. The team said a phased approach is needed: simplify the production process, first apply PHA in high-value sectors such as medical devices and food packaging, then expand into commodity markets.

The research team said AI will be a key driver of biomanufacturing industrialization. AI can optimize the entire biomanufacturing process — from enzyme and microorganism design to digital twins that virtually simulate production and tools that assess economic viability and environmental impact at the same time. This, the team said, can shorten development timelines, lower production costs and improve the odds of successful commercialization.

The significance of the research lies not in developing new production technology but in comprehensively analyzing the conditions for successful biomanufacturing industrialization and presenting a full-cycle roadmap spanning feedstock procurement, microorganism design, fermentation, separation and purification, and market entry. The team said it expects the research to accelerate commercialization of bio-based chemical industries and, in the long run, help shift the petroleum-centered chemical industry toward an eco-friendly bioeconomy.

"The convergence of systems metabolic engineering and AI will be the core technology for resolving these bottlenecks and ushering in the era of biomanufacturing," Lee said.