One of the most interesting projects I worked on at BioPak began with a customer request from an Australian fresh produce supplier called Hydroproduce. What initially started as a bespoke packaging design eventually led to a broader innovation that helped shape BioPak's standard produce packaging range.
The brief was straightforward: develop a moulded fibre packaging solution for fresh fruit and vegetables that aligned with Hydroproduce's sustainability goals while maintaining the durability required for transport and retail display. The material we selected was bagasse — a by-product of sugarcane processing widely valued in sustainable packaging because it transforms agricultural waste into a functional product.
However, during the development process, an interesting technical insight emerged. Traditional bagasse food packaging typically contains two functional additives: one for water repellence and one for grease repellence. Fresh produce, however, contains virtually no oils or grease. As we examined the material requirements more closely, it became clear that the grease-repellent additive was unnecessary for this application.
By removing the grease-repellent additive entirely, we achieved two meaningful outcomes. The first was a significant improvement in environmental credentials — many grease-repellent additives used in fibre packaging contained PFAS (per- and polyfluoroalkyl substances). Eliminating this additive meant the final product could meet compostability certification standards that many other bagasse food packaging products could no longer claim.
The second benefit was cost efficiency. Simplifying the pulp formulation by removing one additive reduced material complexity and allowed for a small but meaningful reduction in production costs — a packaging solution that was both more sustainable and slightly more affordable, without compromising structural integrity.
What began as a bespoke design for Hydroproduce ultimately proved valuable on a much larger scale. The insights gained informed the development of BioPak's standard produce packaging range, now offered as a catalogue product for fresh food suppliers across the industry.