Towards a circular plastics economy: synchronising material design, hybrid processing, digital logistics, and adaptive policy

Abstract The escalating environmental cost of global plastic production is driven by a fundamental misalignment: the complexity of modern polymer chemistry has outpaced the capability of linear waste management infrastructure. Addressing this crisis requires moving beyond fragmented mechanical and thermal solutions to a fully integrated industrial framework that synchronises material innovation with biological discovery. This review articulates a strategic roadmap to transition from a linear disposal model to a robust bio-industrial circular economy, with a predominant focus on the deployment of emerging bio-catalytic and bio-hybrid processing systems. We distinguish between the dual goals of resource recovery (circularity) and safe mineralisation (environmental resilience). Four interdependent pillars essential for this transition are identified: (1) Material design, where “design for degradation” is embedded at the molecular level; (2) Bio-hybrid processing, which supersedes single-mode recycling by synergising biological selectivity with physicochemical throughput (e.g., chemo-biological and photochemical-biological coupling) to handle mixed waste streams; (3) Digital logistics, utilising the “Internet of materials” to enable high-resolution sorting and decentralised processing; and (4) Adaptive policy, where standards are co-developed to verify system compatibility and increased stakeholder engagement. A “paradigm shift” is necessary to align these domains. Only by integrating the material, the process, the data, and the policy can plastic waste be transformed from an environmental liability into a predictable, high-value bio-industrial resource.