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Designing for
End-of-Life

Our engineering team approaches every product with full lifecycle awareness. Design begins not with form or aesthetics but with end-of-life opportunities. We evaluate how products behave in composting environments: fragmentation patterns, microbial breakdown rates, coating interactions, and structural disintegration. These factors shape geometric design, material selection, and manufacturing specifications before we consider commercial requirements. Compostable foodservice ware must perform during use and disappear after disposal.

Composting Resources

Designing Barriers without Persistent Chemicals

We engineer barriers using plant-based coatings: modified starches, protein films, lipid emulsions, and polysaccharide matrices. These are derived from plants but require processing and modification at the molecular level. The distinction matters. These engineered materials perform adequately for many applications. They do not match the performance of petroleum-derived PFAS (forever chemicals) coatings or polyethylene barriers. We accept this limitation. The alternative is introducing persistent chemicals that render products non-compostable regardless of base material.

Barrier Coating Materials

  • Modified starches: Plant-derived moisture barriers for moderate liquid resistance
  • Protein films: Bio-based coatings providing grease resistance and structural support
  • Lipid emulsions: Natural water-repellent barriers from plant oils and waxes
  • Polysaccharide matrices: Complex carbohydrate networks for thermal stability

Achieving Strength Through Design Not Aditives

We design for structural integrity without polymer reinforcement. Conventional packaging achieves strength through synthetic polymer additives: polyethylene coatings, acrylic binders, and styrene-based adhesives. These materials provide excellent performance but persist in composting environments, fragmenting into microplastics that contaminate the environment We achieve strength through fiber orientation, thickness optimization, and geometric design. This is engineering constrained by biology.

Structural Engineering Methods

  • Fiber orientation: Controlled alignment maximizes tensile strength
  • Thickness optimization: Strategic variation balances material use against structural requirements
  • Geometric ribbing patterns: Load distribution through structural design
  • Design constraints: Engineering solutions within biological decomposition parameters

R&D and Supplier Collaboration

Our R&D facility develops products for existing molding equipment with minimal modification. Novel materials requiring specialized equipment remain in laboratory development. This constraint slows innovation but ensures commercial viability and scalability. We source the best available compostable products on the market, establishing partnerships spanning over 20 years with suppliers who share our commitment to material innovation. Through these relationships, we push incrementally toward equipment modifications and process improvements.

Our Operations