Manufacturing Bio-Degradable Cutlery from Sugarcane Bagasse: Upcoming Business for Green India

Suchandra Mukherjee

29 Jun, 2023

The marketof bio-degradable products made from the Sugarcane Bagasseis projected to reach a valuation of USD 322 Million by 2029.Sugarcane bagasse is an amazing alternative for tableware as it is 100% biodegradable, compostable, and chemical-free. Using bagasse products can contribute to the “green living” initiative and help protect our planet. But have you ever wondered how waste sugarcane pulp is transformed into useful Bio-degradable products? Producing Bio-Degradable cutlery from Sugarcane Bagasse involves an advanced process that ensures their functionality, extended lifespan, and durability. In this write-up, we will explore the manufacturing process behind sugarcane bagasse biodegradable cutlery and the required licenses and certifications.

Manufacturing of Bagasse tableware

Bio-Degradable cutlery from Sugarcane Bagasse, also biodegradable cutlery, serves as an environmentally friendly alternative to single-use products. It is an entirely natural and renewable resource for single-use food packaging that does not contribute to pollution. If you prioritize environmental consciousness, sugarcane bagasse dishware is the perfect choice. It is crafted from organic sugarcane fibre, ensuring a healthy and non-toxic dining experience. Sugarcane plants are rapidly renewable resources that can regrow within a short span of 10 to 12 months. Using disposable bagasse products, you actively support plant growth, foster a healthier lifestyle, and contribute to a sustainable ecosystem.

Manufacturing Process of Bio-Degradable cutlery from Sugarcane Bagasseis

The manufacturing process of Bio-Degradable cutlery from Sugarcane Bagasseis as follows:

1. Bagasse collection: The initial step involves gathering sugarcane bagasse, the residue left after extracting juice from the sugarcane plant. The collected bagasse is then transported to the factory for further processing.
2. Screening and Cooking: The second stage in manufacturing bagasse tableware is screening and cooking. The sugarcane pulp undergoes an initial screening process to assess the fibre quality. Additionally, the bagasse is cooked to enhance the strength and resistance of the pulp fibres.
3. Moulding the pulp: The sugarcane bagasse pulp is diluted and moulded using advanced moulding equipment. This step involves creating the wet embryos of various products by shaping the bagasse pulp into the desired forms. Subsequently, the semi-wet pulp undergoes vacuum dehydration to remove excess water.
4. Pressing the pulp: During this phase, the dehydrated pulp is pressed into different moulds for bagasse flatware under high temperature and pressure. The high-temperature pressing ensures the resilience and durability of the partially finished product.
5. Trimming and Shaping: Any rough edges or imperfections are smoothed out after the bagasse has been pressed into various disposable food packaging items. Trimming is carried out to refine the appearance of the final product.
6. Final inspection: The Quality Control (QC) team thoroughly inspects the finished products following the shaping process. They conduct pH, moisture, and scuff resistance tests to analyze the performance of the items. Additionally, they check for any scratches, dents, or poor finishing before packaging. In the final step, the products are sanitized and sterilized to eliminate bacteria or harmful toxins.

But sugarcane bagasse waste for food packaging?

The advantageous qualities of Bio-Degradable cutlery from Sugarcane Bagasse that make them an excellent and environmentally friendly choice are as follows:

•  Completely natural: It’s true sugarcane bagasse food products are 100% natural. The main components of bagasse are cellulose, hemicellulose, lignin, and wax. They do not contain any chemical lining, resin coating, or toxic binders.

• Zero waste: Sugarcane pulp products generate no waste from manufacturing to usage. All components of the sugarcane plant, including bagasse ash, bagasse, and molasses, are utilized for various purposes.

• Environmentally conscious: Bagasse products are compostable, meaning they do not harm the environment. They are carbon offset, recyclable, and renewable, making them ideal choices for environmentally conscious consumers.

• Highly resistant: Sugarcane bagasse products exhibit excellent resistance to a wide temperature range, from -25°C to 220°C. They can withstand water, hot oils, and grease. These products are safe to use in refrigerators and microwaves. Additionally, bagasse flatware is spill-proof, leak-resistant, and does not absorb liquids.

How is biodegradable bagasse Cutlery made?

The entire process of manufacturing Bio-Degradable cutlery from Sugarcane Bagasse is free from the use of chemicals. Let ussee how bagasse tableware is produced:

• The first step involves collecting sugarcane pulp, which is then cooked and crushed to prepare the sugarcane fibres for further processing.
• The prepared sugarcane pulp is then transferred to moulding equipment, where wet embryos are formed.
• The wet pulp undergoes dehydration in a vacuum dehydration machine.
• The semi-wet sugarcane pulp is then dried at high temperatures before being pressed into moulds.
• Once the pulp has been pressed into moulds, it takes the shape of different tableware products such as clamshells, containers, plates, trays, sauce cups, and cutlery.
• Raw edges of the dishware products are trimmed, and an inspection team ensures the quality of the final product.
• In the final stage, the products undergo sanitization and sterilization before being packaged for distribution.

Advantages of Bio-Degradable Cutlery from Sugarcane Bagasse

As awareness grows about the impact of plastic, people are seeking greener alternatives to reduce plastic consumption. While there are several eco-friendly dinnerware options available, such as bamboo, birchwood, and palm leaf, bagasse flatware products stand out as the most environmentally friendly and safe substitute for the following reasons:

• Eco-friendly: Biodegradable bagasse tableware does not rely on fossil fuel energy, significantly reducing airborne pollution. These products generate no waste and do not contribute to land or ocean pollution. Switching to bagasse tableware can help decrease the presence of greenhouse gases in the environment. Additionally, sugarcane pulp dinnerware serves as a tree-free alternative that helps preserve natural habitats.

• Compostable: The exceptional characteristic of bagasse flatware is its compostability. After composting, Bagasse dishware products break down in the soil and enrich plants with nitrogen. They readily decompose in both home and commercial composting settings. Bagasse products take only 1 to 3 months to fully decompose into nutrient-rich plant compost, promoting optimal plant growth and preventing soil erosion^[1].

• Reliability: Reliability is a significant strength of biodegradable bagasse tableware. Sugarcane flatware is highly durable and resistant, holding hot food up to 100°C. Bagasse products are spill-proof and leak-resistant. They can be safely used in microwaves for reheating purposes and are suitable for cold storage in refrigerators.

• Chemical-free: Sugarcane fibre dinnerware is 100% free from chemicals. These products are not treated with harsh chemicals like chlorine bleaching. Moreover, bagasse products do not contain any plastic or resin coating to enhance durability. They are naturally robust and resistant.

Applications of Bio-Degradable cutlery from Sugarcane Bagasse

Sugarcane bagasse food packaging finds utility across various food sectors. Here are some typical uses of compostable disposable bagasse products:

• Takeaway and food delivery: Bagasse products are commonly used for packaging food items for takeout and delivery purposes.
• Travel food carrying: Bagasse containers are convenient for carrying food while travelling.
• Dine-in and food service: Bagasse tableware is suitable for use in restaurants and other dining establishments to serve food to customers.
• Cold storage: Bagasse products can be safely used for storing food in refrigerators and freezers.
• Caterers, restaurants, and coffee shops: Bagasse packaging is widely utilized in the food service industry, including catering services, restaurants, and coffee shops.
• Outdoor parties and events: Bagasse tableware is an excellent option for serving food at outdoor gatherings, parties, and events.

Licenses and certifications

According to Rule 3(e) of the PWM (Plastic Waste Management) guidelines, compostable plastic undergoes biological processes in composting and breaks down into CO2, water, inorganic compounds, and biomass. This decomposition rate should align with other known compostable materials. The PWM (Second Amendment) Rules, 2022, further define biodegradable plastic as plastics, excluding compostable plastics, that degrade through biological processes under regular environmental conditions. They should not leave any visible, distinguishable, or toxic residue that could harm the environment. The Central Pollution Control Board (CPCB) is responsible for issuing the Biodegradable and Compostable Plastic Certificate, enabling the production and trade of compostable materials, as outlined in Rule 4(h) of the PWM Rules, 2016.

The following are the required documents for manufacturers and sellers of Bio-Degradable cutlery from Sugarcane Bagasse:

• Company PAN (Permanent Account Number) & GST (Goods and Services Tax) details
• Aadhaar of the authorized person
• Process flow diagram depicting the manufacturing process
• NOC (No Objection Certificate) for Air and Water Pollution Control issued by the concerned State Pollution Control Board (SPCB) or Pollution Control Committee (PCC)
• Registration certificate for producing biodegradable commodities carry bags, or both, issued by the concerned PCC/SPCB under Rule 13(i) of the Plastic Waste Management Rules, 2018
• Geo-tagged pictures of the storage area, raw materials, production area, and product dispatch area
• Geo-tagged pictures of the plant machinery
• Copy of the electricity bill
• Proof of installation of pollution control devices or measures
• Documents supporting the procurement of raw materials
• Test reports conducted according to the Indian Standards IS/ISO 17899:2022. The testing should be carried out at CIPET (Central Institute of Plastics Engineering & Technology) or a recognized laboratory under the Laboratory Recognition Scheme, 2020, of the Bureau of Indian Standards (BIS) or laboratories accredited by the National Accreditation Board for Testing and Calibration Laboratories.

These documents are necessary to comply with regulations and ensure the proper production and sale of compostable and biodegradable items.

Conclusion

Today’s generationis increasingly adopting environmentally friendly options over plastic and single-use products. Bagasse tableware products offer a biodegradable, natural, and non-toxic alternative. They are designed to resist cuts and grease, ensuring enhanced safety and reliability. It is recommended to take expert advice for registering a business dealing with Bio-Degradable cutlery from Sugarcane Bagasse to have all the compliances and paperwork in place.

FAQ

Read our Article: Biodegradable And Compostable Plastic Bags Manufacturing From Corn & Cassava Starch