Advances in Algae-Based Bioplastics: From Strain Engineering and Fermentation to Commercialization and Sustainability

The development of algal bioplastics offers a promising pathway toward sustainable materials that can mitigate reliance on fossil fuel-derived plastics. This article reviews recent advances in algal cultivation, strain optimization, biopolymer extraction, and processing technologies, alongside techno-economic and life cycle assessments. Special emphasis is placed on integrated biorefinery models, innovative processing techniques, and the role of government–industry–academia partnerships in accelerating commercialization. The analysis incorporates both demonstrated algal systems and theoretical applications derived from established microbial processes, reflecting the emerging nature of this field. The environmental advantages, market readiness, and scalability challenges of algal bioplastics are critically evaluated, with reference to peer-reviewed studies and industrial pilot projects. The analysis underscores that while technical feasibility has been demonstrated, economic viability and large-scale adoption depend on optimizing yield, reducing production costs, and fostering collaborative frameworks. Future research priorities include enhancing strain performance via AI-enabled screening, expanding product valorization streams, and aligning regulatory standards to support global market integration.