Sustainable Methods for Conversion of Cellulosic Biomass to Bio-Based Plastics: A Green Chemistry Approach

Plastic manufacturing depends heavily on petroleum-derived monomers like terephthalic acid, the main component of polyethylene terephthalate (PET). However, the depletion of fossil resources and increasing environmental concerns have heightened the need for sustainable alternatives. Lignocellulosic biomass has emerged as a promising resource due to its renewable, abundant, and eco-friendly nature. Understanding its chemical composition enables conversion of this biomass into platform chemicals, such as 2,5-furandicarboxylic acid (FDCA) and lactic acid, derived from cellulose and hemicellulose. These can be polymerized into bio-based plastics such as polyethylene furanoate (PEF), polylactic acid (PLA), and polyhydroxyalkanoates (PHAs), offering greener alternatives to fossil-based plastics. PEF features rigid furan rings that enhance thermal stability, mechanical strength, and barrier properties, and reduce gas permeability compared to PET. PLA is a renewable, biodegradable plastic widely used in packaging and medical applications. This review covers the chemical composition of lignocellulosic biomass cellulose, hemicellulose, and lignin, and various pretreatment strategies, chemical, physicochemical, and physical, to overcome biomass recalcitrance and improve conversion efficiency. It also highlights recent catalytic advances in transforming cellulosic carbohydrates into bio-based plastic precursors such as FDCA and lactic acid. Lastly, this review discusses polymerization pathways for producing PEF and PLA, emphasizing their role in reducing the environmental impact of polymer manufacturing and promoting green chemistry principles.