Biotech startup converts waste into bioplastics

September 23, 2025

A pioneering German biotech startup is revolutionizing the chemical industry by converting industrial waste into high-value, eco-friendly materials using a unique black yeast-like fungus.

Biophelion: a spin-off driving circular biomanufacturing

The startup, Biophelion, emerged from the Leibniz Institute for Natural Product Research and Infection Biology (Leibniz-HKI) in Jena. It was launched in response to the Circular Biomanufacturing Challenge organized by the Federal Agency for Breakthrough Innovations (SPRIND).

By developing cutting-edge biotechnological processes, Biophelion transforms carbon-heavy industrial byproducts into recyclable platform chemicals. This approach could help decarbonize the chemical industry—a sector responsible for nearly 5% of global CO₂ emissions—and set new standards for sustainable manufacturing.

According to future CEO Lara Regestein, SPRIND provided the startup with critical support in strategy, funding, and research momentum.

Harnessing the power of black fungus

At the heart of Biophelion’s innovation is a black yeast-like fungus known for its ability to thrive in extreme and toxic environments. This microorganism has remarkable metabolic flexibility, enabling it to break down carbon-rich waste streams from industries such as:

• Bioethanol production
• Sugar processing
• Paper manufacturing

Instead of releasing carbon into the atmosphere as CO₂, the fungus converts waste into valuable, bio-based compounds, effectively closing the carbon loop.

From pollution to production: key sustainable compounds

Biophelion’s process produces three essential compounds from waste materials:

1. Bio-based polyester – a renewable alternative for sustainable packaging.

2. Pullulan – an edible polymer already used in the food industry, now being tested for 3D printing applications.

3. Novel surfactants – biodegradable alternatives to conventional chemicals found in detergents and dishwashing liquids.

Unlike traditional chemical manufacturing, which demands high energy and often produces toxic byproducts, Biophelion’s method is clean, circular, and energy-efficient.

 “We are developing applications that were previously unimaginable—especially with pullulan and our surfactant molecule,” said Till Tiso, co-founder and future CTO of Biophelion.

Rethinking plastics and 3d printing

One of the most promising aspects of Biophelion’s work lies in sustainable plastic alternatives. The startup is exploring the potential of pullulan as a 3D printing material, aiming to replace petroleum-based plastics in the rapidly expanding additive manufacturing industry.

Looking ahead, the company envisions building 3D-printed bioreactors from pullulan—reactors capable of producing not only sustainable materials but also their own production environment.

Meanwhile, the development of biodegradable surfactants could drastically reduce the ecological impact of everyday cleaning products, preventing toxic chemicals from polluting waterways.

Strategic location for growth and collaboration

Biophelion is headquartered at the BioInstruments Center on the Beutenberg Campus in Jena, in close proximity to Leibniz-HKI. This location enables continuous scientific collaboration as the startup scales its processes and optimizes its fungus-based biotechnology.

Leibniz-HKI Director Axel Brakhage, PhD, praised the founders for their scientific excellence and entrepreneurial courage:

 “We are proud to continue supporting the Biophelion team as they bring their innovations to market. We wish them every success in shaping a sustainable future.”