As part of my work at BioPak, I led the design and development of a compostable oyster tray solution for Blue Harvest — an Australian seafood producer looking to transition away from conventional plastic packaging. My role centred on solving a very specific design challenge: how to replicate the performance of a thermoformed plastic tray using moulded fibre, while improving functionality where possible.
The starting point was not the material, but the product itself. Oysters are inherently irregular in form, yet they loosely follow an 'egg-like' geometry. I worked closely with Blue Harvest, who provided detailed sizing charts across different oyster grades. This allowed me to analyse the dimensional range and identify a consistent form factor that could accommodate the majority of oysters within a single tray design — a cavity structure inspired by the organic egg shape.
Translating this into bagasse presented unique challenges. Unlike thin plastic trays, bagasse is thicker, more rigid, and less forgiving in fine detailing. Rather than attempting to directly replicate plastic, I approached the design from first principles — rethinking how structure, strength, and product fit could be achieved using fibre. The tray was engineered with considered wall geometry and subtle ribbing to maintain integrity under load, while still allowing oysters to sit naturally within the cavities.
One of the key advantages of moving to a more rigid material was the opportunity to introduce a lid system — something that was not feasible with the previous thin plastic trays. By designing a defined rim profile, I enabled compatibility with a fitted lid in PET or PLA. This significantly improved protection during transport, stackability, and retail presentation, while also streamlining logistics handling through supply chains.
From a commercial standpoint, the bagasse tray did come at a premium compared to standard plastic alternatives. However, the sustainability benefits were substantial. Many oyster trays on the market are produced in dark plastics, which are not recyclable within Australian waste streams due to limitations in sorting technology. By transitioning to plant-fibre, the solution provided a compostable end-of-life pathway aligned with both regulatory direction and consumer expectations.
This project reflects a broader approach I take to design — one that balances creative thinking with manufacturing reality. It wasn't simply about replacing plastic with a different material, but about understanding the full system: product behaviour, material constraints, tooling capabilities, and supply chain requirements. The success of this project came from rethinking the fundamentals — using design as a tool to bridge the gap between sustainability ambition and real-world execution.