Beyond fossil plastics: next-generation PLA-based bio-packaging for industrial applications – advances, challenges, and data-driven insights

The accumulation of conventional plastics has increased the need for sustainable alternatives, particularly those derived from renewable resources. Among these, polylactic acid (PLA)-based industrial materials have emerged as prominent candidates for replacing conventional plastics in various applications. PLA, a biodegradable and compostable polymer synthesized from renewable resources, such as cornstarch and sugarcane, offers several advantages, including environmental friendliness and lower greenhouse gas emissions. This review examines the current state of PLA-based bio-packaging materials, focusing on their features, production processes, and performance in comparison to traditional plastics. This review discusses advancements in PLA technology, including routes for enhancing its mechanical strength, thermal stability, and barrier properties, which are critical for its application in various packaging scenarios. Additionally, this review addresses the challenges associated with PLA, including its limited availability, higher cost compared to conventional plastics, and issues related to its end-of-life disposal and recycling.