Microbial production of poly (3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) as a sustainable alternative to petroleum-based plastics: Advances, challenges, and prospects

The depletion of fossil fuel reserves in the coming decades highlights the urgent need for sustainable alternatives to petroleum-based plastics. Among biodegradable biopolymers, poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), a member of polyhydroxyalkanoates (PHAs), has gained significant attention due to its eco-friendly nature and desirable material properties. PHBV exhibits superior mechanical strength, thermal stability, and biodegradability, making it a viable candidate for applications in agriculture, medicine, and food packaging. Microbial fermentation enables the production of both PHB and PHBV with similar efficiency, depending on substrate availability. However, commercial scalability remains a challenge due to high production costs, limited feedstock availability, and suboptimal yields. Advances in fermentation strategies, metabolic engineering, and the utilisation of cost-effective carbon sources are actively being explored to enhance PHBV production efficiency. Additionally, industry-academia collaborations and open innovation play a crucial role in overcoming existing limitations, driving technological breakthroughs, and facilitating the commercialisation of PHBV. This review provides an updated perspective on the latest advancements, challenges, and prospects of microbial PHBV production, highlighting its potential as a sustainable alternative to conventional plastics. • PHBV is a promising biodegradable alternative to petroleum-based plastics with excellent mechanical and thermal properties. • Microbial fermentation enables efficient PHBV production, but costs and yields limit commercial scalability. • Advances in metabolic engineering, fermentation strategies, and low-cost feedstocks are improving production efficiency. • Industry–academia collaborations are crucial for overcoming challenges and driving PHBV commercialization. • PHBV shows strong potential for sustainable applications in packaging, agriculture, and medicine.