Papyrus Australia develops banana fiber clamshells from agricultural waste in Egypt

14 Jan 2022 --- Agricultural waste fiber technologists Papyrus Australia is unveiling the “world’s first” fully banana fiber-based clamshell, produced in a molded fiber packaging facility in Sharqiah, Egypt.

Edward Byrt, chairman of Papyrus Australia, tells PackagingInsights: “Banana waste is a superior natural fiber possessing unique properties, which make it suitable for processing by utilizing our patented intellectual property and ultimately, for molding to produce food quality packaging, displacing plastic packaging.”

Papyrus Australia can now:

• Produce 6,300 clamshells per hour from its fiber packaging facility.
• Provide these samples to potential clients, including those interested in establishing a banana fiber food packaging facility. 
• Supply surplus output under an “off-take” agreement to the Halim family operation Al Ahram.

Zero waste strategy
Byrt explains the business leaves no banana plantation waste behind when producing the clamshells.

“We use all banana plantation waste, with the majority of fiber coming from the banana tree trunk. This material is otherwise left to rot in the plantation, emitting methane gas, which contributes to global warming,” he explains.

The chairman continues by explaining the retrieval of the banana plantation waste and the company’s patented process stops the natural degradation and associated methane gas emissions entering the atmosphere. 

He calls this another “carbon asset” of the process, which the company is also planning to monetize.

A diagram illustrating Papyrus Australia’s production process in Sharqiah, Egypt.

Grand ambitions 
Papyrus Australia will continue to pursue new business opportunities through technical guidance under a contractual arrangement, where the investor pays for the patented machinery and all requisite equipment is manufactured by Papyrus in Adelaide, Australia. 

“The entry cost will be not less than AUD 5 million (US$3.6 million) upward. This is not for a future ‘cottage industry,’ but rather a sophisticated commercial operation to process banana plantation waste to make several products,” Byrt tells says. 

“The molded fiber food packaging to replace plastic packaging is just one product. Others include banana veneer to replace timber veneer as a decorative element in furniture, flooring, ceiling tiles, panel board of all densities, including MDF panelboard, paper and cardboard and kraft paper products, natural liquid fertilizer (known as MUSA), and fibrous agri-products to replace peat for deficient sandy soils,” he adds.

Banana fiber molded clamshells.Negotiating partnerships
Byrt says the company is now actively negotiating with a packaging outfit in Egypt and assisting their transfer from plastic to fiber packaging. 

“We are also fielding enquiries from several banana-growing countries such as Sudan, India, the Philippines and Central America,” he shares.

Looking ahead
The Sharqiah Egypt operation is a demonstration project, and Papyrus Australia plans to return to its homeland for further expansions.

“We expect further factories in Egypt in the short term, and we are committed to returning to Australia to establish the first Australian commercial banana plantation waste processing and banana fiber product manufacturing enterprise,” notes Byrt.

“Australia is the only developed economy where bananas are grown commercially – all other countries with plentiful banana crops, or appropriate climate and environment, are developing economies.”

By Natalie Schwertheim