One of the most meaningful projects I have worked on at BioPak was the development of the world's first compostable Holy Communion cup — a fibre-based alternative to the small single-use plastic cups traditionally used in churches worldwide.
Across thousands of congregations, millions of small plastic communion cups are used each year. While individually small, their cumulative environmental impact is significant — and until now, there had been no viable compostable alternative that met functional, hygienic, and ceremonial requirements.
From a structural standpoint, the cup needed to be lightweight yet rigid, stackable for mass distribution, comfortable to hold, and capable of containing liquid without leaking or softening prematurely. Unlike larger foodservice packaging, this format operates at a very small scale — which introduces manufacturing constraints around wall thickness, mould detail, and fibre consistency.
Working within BioPak's New Product Development team, I contributed to the structural optimisation and manufacturability of the bagasse fibre solution. The challenge was ensuring liquid resistance without relying on traditional plastic linings that would compromise compostability. This required close collaboration with manufacturing partners to fine-tune mould tooling, fibre density, and finishing techniques.
Another key consideration was user experience. Communion is a ritual rooted in tradition. The new cup needed to feel respectful, discreet, and familiar — not experimental. Proportions, lip thickness, and stability were refined to ensure ease of handling during services.
This project stands as an example of purpose-driven design — applying engineering and material science to create solutions aligned with both environmental stewardship and community values. It was a reminder that design can quietly reshape everyday systems, even those rooted in centuries of tradition.