The development of biodegradable and compostable alternatives to fossil-derived plastics is critical for advancing sustainable packaging and textile applications. While PHA offers home compostability, it presents processing challenges, whereas PLA has well-established processability but limited home compostability. NIRI has developed staple fibres from compounded PHA/PLA polymer blends, optimising their performance, scalability, and suitability for packaging applications. This presentation will explore key challenges and breakthroughs in polymer and process development, as well as composition refinement and intelligent fabric design to achieve enhanced heat-sealability, formability, whilst improving the home compostability of PLA. By tailoring staple fibre geometries, NIRI enables compatibility with different nonwoven processing techniques, including carded, airlaid, and wetlaid systems, each offering unique performance benefits for packaging applications. NIRI’s research demonstrates how advanced fibre engineering can deliver scalable, high-performance biopolymer innovation, helping to replace conventional thermoplastics while maintaining industrial viability and environmental sustainability.