Process optimization, metabolic engineering interventions and commercialization of microbial polyhydroxyalkanoates production – A state‐of‐the art review

Abstract Background Microbial polyhydroxyalkanoates (PHAs) produced using renewable resources could be the best alternative for conventional plastics. Despite their incredible potential, commercial production of PHAs remains very low. Nevertheless, sincere attempts have been made by researchers to improve the yield and economic viability of PHA production by utilizing low‐cost agricultural or industrial wastes. In this context, the use of efficient microbial culture or consortia, adoption of experimental design to trace ideal growth conditions, nutritional requirements, and intervention of metabolic engineering tools have gained significant attention. Purpose and scope This review has been structured to highlight the important microbial sources for PHA production, use of conventional and non‐conventional substrates, product optimization using experimental design, metabolic engineering strategies, and global players in the commercialization of PHA in the past two decades. The challenges about PHA recovery and analysis have also been discussed which possess indirect hurdle while expanding the horizon of PHA‐based bioplastics. Summary Selection of appropriate microorganism and substrate plays a vital role in improving the productivity and characteristics of PHAs. Experimental design‐based bioprocess, use of metabolic engineering tools, and optimal product recovery techniques are invaluable in this dimension. Conclusion Optimization strategies, which are being explored in isolation, need to be logically integrated for the successful commercialization of microbial PHAs.