W-Cycle creates compostable sugarcane containers for upcycled energy savings

22 Sep 2020 --- Israeli food-tech start-up W-Cycle has developed SupraPulp, an energy- and water-saving bioplastic made of 99.99 percent bagasse, the dry pulpy residue left after the extraction of juice from sugarcane.

The upcycled sugarcane containers were designed to replace conventional plastic, aluminum, or foam containers and are suitable for greasy, wet or hot food.

“An abundant by-product of the sugarcane industry, most sugarcane bagasse ends up in landfills or is burned,” Joseph Siani, chief technical officer and co-founder of W-Cycle, tells PackagingInsights.

“The ratio of extracting cellulose from sugarcane waste is 45 percent, or 450 kg can be extracted out of 1 metric ton of waste. We can also use any other feedstock: reed, wood, banana leaves – any fiber can form the shape of the product and provide its mechanical properties.”

While standard pulp products cannot sustain liquids and oils, SupraPulp containers are oil- and water-resistant and avoid any absorption or leakage. They are also non-coated, toxin- and metal-free.

Redefining bioplastics
In terms of cost intensitivity, SupraPulp is “similar in price,” if not “cheaper than crystallizable PET plastic and definitely [cheaper] than recycled PET.”

“Low grade plastics can indeed be cheaper, but those types cannot handle hot food or may turn brittle in the freezer,” Siani adds.

SupraPulp was designed to prevent the absorption of meat juices to prevent leakages.SupraPulp has been in development since 2017. Siani explains he was working in the bio-packaging sector when the Israeli government challenged the industry to design a replacement for the millions of plastic food trays used in Israeli schools.

A lacking compostable solution that can hold hot and greasy food – especially throughout transportation – motivated him to develop SupraPulp.

W-Cycle’s SupraPulp material can be frozen to -40°C and reheated to 270°C, inviting a comprehensive range of food applications. Packaged food with SupraPulp can be frozen and heated with ovens, convection ovens, steam cookers or microwaves. After use, the package can be disposed of as organic waste.

While bioplastics have been hailed as a competitive alternative to plastic packaging, Siani notes that they can be resource-intensive.

“Bioplastics take a lot of energy to manufacture as well as water. In the process of growing corn for bioplastic, pesticides are used and those go into the earth. At W-Cycle, we use an abundant waste product to create compostable packaging, taking as little as possible and leaving a minimal mark on the planet.”

Upcycling innovation
The packaging industry is increasingly experimental with upcycling materials to address consumer and regulatory demands to protect the environment.

MarinaTex, a bioplastic made from fish waste, could provide an environmentally-friendly alternative to single-use plastics. The biodegradable material is resource-light and requires little energy to be produced.

Poland-based biodesign consultancy MakeGrowLab shared in April how its customizable, home-compostable plastic alternatives circumvented COVID-19-induced supply chain disruptions by sourcing its upcycled food waste materials locally.

Meanwhile, research from Yokohama National University, Japan, showed that used coffee grounds could be upcycled to serve as a new non-wood source. The research team found that the amount of cellulose in coffee grounds per gram of dry weight is much lower than that of wood and could contribute to developing sustainable green chemistry.

By Anni Schleicher

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