In the global shift towards sustainable living, the foodservice industry is embracing eco-friendly alternatives to traditional plastic tableware. Sugarcane bagasse, the fibrous residue left after extracting juice from sugarcane stalks, has emerged as a promising material for biodegradable and compostable tableware. However, a common question arises: How does this natural material resist water and oil without compromising its environmental benefits?
At InNature Pack, we have developed a multi-faceted approach that enhances the water and oil resistance of sugarcane bagasse tableware while maintaining its compostability. In this article, we’ll explore how we achieve water and oil resistance through advanced manufacturing, smart material engineering, and targeted surface treatments—while remaining true to our sustainable mission.
Why Water and Oil Resistance Matters for Disposable Tableware
In real-world foodservice applications—hot soups, greasy dishes, oily snacks—tableware must withstand moisture and oil exposure without softening, leaking, or losing its shape. For traditional plastic products, this is easy—but at an environmental cost. For natural fiber-based alternatives like sugarcane bagasse, achieving similar performance requires a deeper understanding of fiber chemistry and processing.
Our R&D team has worked extensively to overcome this technical challenge without sacrificing compostability or safety. What follows is a breakdown of our three-pronged solution: structural engineering, material modification, and optional coatings.
Core Manufacturing Advantage: Naturally Dense Structure
The first line of defense against water and oil lies in how the product is formed.
At InNature Pack, we use a high-pressure thermoforming process, applying temperatures between 180–200°C. This step is more than just shaping—it’s a transformative process that impacts the microstructure of the product.
Under these conditions, the cellulose fibers in the bagasse undergo hydrogen bonding, where hydroxyl groups on the fiber surfaces form intermolecular bridges. These natural bonds pull the fibers tightly together, reducing gaps and creating a low-porosity structure that acts as a physical barrier to water and oil.
This dense matrix is the foundation of our resistance performance. Unlike low-pressure molded pulp products (such as traditional egg cartons), our high-pressure bagasse items have a noticeably smoother surface, stronger edges, and enhanced barrier properties—all achieved without synthetic liners.
Reinforced Material Engineering: Fiber Blending for Strength & Resistance
To further enhance durability and liquid resistance, we apply fiber optimization techniques during pulping.
Our formula involves blending short sugarcane fibers with long bamboo fibers. Here’s why:
- Long bamboo fibers act like a skeletal framework, reinforcing the structure and improving tensile strength.
- Short sugarcane fibers fill the interstitial gaps, creating a compact network that leaves minimal space for moisture or oil to seep in.
This complementary fiber arrangement creates a mechanically robust and chemically stable substrate that delays liquid penetration—especially useful for holding hot or greasy foods for extended periods.
Scientific literature supports this approach. Fiber hybridization has been shown to improve both wet and dry strength, while reducing the overall water absorption rate of molded pulp products (ScienceDirect, 2020).
Material Modification: Food-Safe Additives
Beyond physical structure, we also modify the internal chemistry of the material by introducing food-grade hydrophobic agents during pulp preparation.
A key example is alkyl ketene dimer (AKD), a compound widely used in the paper industry. When added to the pulp slurry, AKD forms covalent bonds with the hydroxyl groups in cellulose. This reaction reduces the surface energy of the fibers, making them inherently water-repellent.
The advantages of internal sizing include:
- Even distribution throughout the material, not just the surface.
- Retention of compostability and recyclability.
- Durability against hot liquids and mildly acidic or alkaline foods.
All additives used by InNature Pack are BfR and FDA-compliant, ensuring complete food safety.
Optional Surface Treatments: Laminations & Coatings
For applications that demand enhanced water and oil resistance—such as takeaway containers for hot, greasy foods or utensils requiring high stiffness—optional surface treatments are available. These solutions preserve the compostability of molded fiber products while offering additional performance.
Biodegradable Lamination
Lamination involves adhering a thin layer of biodegradable film (often PLA or PBAT-based) onto the molded pulp surface. This method offers superior barrier properties compared to coatings and results in a smoother, glossier finish. Lamination is commonly used for premium or delivery-focused packaging that demands extended resistance to leakage or contamination.
- Pros: Strong, consistent liquid/oil barrier; longer hold times; better surface aesthetics
- Cons: Slightly higher cost; may impact composting speed if not properly managed
Water-Based or Bio-Based Functional Coatings
This involves applying a biodegradable, water- and oil-resistant coating to the surface of the molded product after thermoforming. Commonly used coatings include water-based dispersions and biopolymer layers . Surface coating creates a protective film that helps reduce liquid absorption and improve resistance to grease—particularly valuable for foods with prolonged contact or higher oil content.
While coatings are effective, they can wear off more quickly under high-moisture or prolonged use conditions compared to laminated surfaces. We recommend using these coatings only when necessary to ensure the product remains lightweight, food safe and compostable.
Environmental Compliance and Sustainability
Sustainability is at the core of our operations. All materials and additives used in our tableware are certified compostable, meeting international standards such as EN13432. Under industrial composting conditions, our products break down into carbon dioxide, water, and biomass within 90 days, leaving no toxic residues.
Furthermore, our manufacturing processes are designed to minimize environmental impact. We employ closed-loop water systems and energy-efficient machinery to reduce resource consumption. By utilizing agricultural by-products like bagasse and bamboo fibers, we contribute to waste reduction and promote the circular economy
Limitations & Ongoing Innovations in the Industry
Despite ongoing improvements, molded fiber tableware—like all materials—has its limitations under extreme use conditions:
- Prolonged contact with oily foods exceeding 100°C may eventually compromise performance, particularly for uncoated products.
- High-performance surface treatments can increase unit costs by 30–50%, though prices are gradually declining as technology matures and scales improve.
That said, the industry continues to explore advanced solutions aimed at balancing functionality and sustainability:
- Nano-fiber reinforcement technologies are being studied to enhance tensile strength and reduce material porosity at the micro level.
- Bio-based polyurethane blends show potential for creating durable, compostable coatings with higher thermal and grease resistance.
- Surface texture optimization—such as ribbing or micro-patterns—is being investigated to delay oil pooling and improve structural rigidity.
These ongoing efforts across the fiber packaging sector are expected to broaden application scenarios, especially in foodservice, without compromising environmental benefits.
Conclusion
Sugarcane bagasse tableware represents a sustainable and practical solution for the foodservice industry. Through advanced manufacturing techniques, material modifications, and optional surface treatments, we have developed products that meet the demands of modern foodservice while aligning with environmental goals.
At InNature Pack, we are committed to continuous innovation and sustainability. Our approach ensures that you don’t have to compromise between performance and environmental responsibility.
Interested in learning more or requesting samples? Contact us today to explore how our sugarcane bagasse tableware can meet your needs.
FAQ
Q: Can bagasse tableware handle hot and oily foods?
A: Yes. Our tableware is designed to withstand hot liquids and oils up to 100°C without leaking or deforming, thanks to the combination of dense fiber structures and hydrophobic additives.
Q: Are the additives used safe for food contact?
A: Absolutely. All additives are food-grade and comply with international safety standards. They do not affect the taste or safety of the food.
Q: Is the tableware microwave and freezer safe?
A: Our products are microwave-safe for reheating purposes and can be used in freezers without compromising structural integrity.
Q: How should the tableware be disposed of?
A: After use, the tableware can be composted in industrial composting facilities, where it will break down into natural components within 90 days.
