One of the more technically nuanced projects I contributed to at BioPak involved designing a fibre-based produce packaging solution for Kapiris Bros, a major fresh produce supplier in Australia. On the surface, the packaging appeared simple — moulded bagasse trays designed to hold fruits and vegetables. But beneath that simplicity sat an important material breakthrough.
Traditional bagasse food packaging typically contains two functional additives: a grease-repellent additive to resist oils and fats, and a water-repellent additive to maintain structural integrity in moist conditions. For hot or oily foods, both are necessary. But fresh produce does not generate grease.
By re-evaluating the actual functional requirements of produce packaging, we identified an opportunity: eliminate the grease-repellent additive entirely and retain only water resistance. Several years earlier, we had discovered that many grease-repellent additives used in fibre packaging across the industry contained PFAS (per- and polyfluoroalkyl substances) — these 'forever chemicals' persist in the environment and have raised global health and regulatory concerns.
My role in this project centred on validating performance and ensuring manufacturability while maintaining structural strength and durability for retail distribution. Removing an additive changes material behaviour. We needed to ensure the trays would maintain rigidity under cold-chain storage conditions, resist moisture from fresh produce, and perform reliably through transport and stacking.
An additional benefit of removing the grease-repellent additive was alignment with Australian home compostability standards. Without added PFAS chemistry, this range could confidently meet criteria for home compost systems — expanding end-of-life options for consumers and strengthening environmental claims.
What makes this project meaningful is that it reflects a broader principle: sustainable innovation is often about subtraction, not addition. Instead of layering more materials or coatings onto a product, we simplified the formulation. Small formulation changes translate into significant cumulative impact at scale.