Biosphere Industries, set up three years ago by the team as a research company for environmentally friendly packaging, says its disposable baking pan, suitable for a range of baked foods such as pies and cakes, could sell for half the price of ovenable plastics and produce cost savings of 20 to 30 per cent compared to aluminium trays.
The company may also be helped by rising aluminium prices, recently cited by US metal and oil company Hydrol as driver of its three-quarter profits. At the start of October, it said aluminium was trading between $1,700 and $1,900 per ton in a very volatile market, supported by declining stocks and continuing short-term supply disruptions.
Elie Helou, Biosphere's chief executive, said his firm's baking pan was made from the company's newly developed Primary Packaging Material 100 (PPM100) which consists mainly of starch with a small amount of organic additives and non-wood fibres to add structure. No non-organic fillers or plastics have been used.
He said the material was rigid in design and should biodegrade within 60 days of composting. "We are seeking our own protection for the mix and mould systems which produce steam as the only by-product of manufacture. We believe that our technology is several years ahead of current competitors and intend to take advantage of this lead."
Helou believes the low price and functionality of the baking pan can give it the competitive edge. "In the past, manufacturers offering biodegradable alternative packaging went to market with a non price competitive product and expected consumer and end users to pay for the biodegradability features. We try to offer solutions where customers do not have to change anything."
But PPM100, which can also be used for a range of foods, from salads to ice cream, is still more expensive than Styrofoam packaging, a form of expanded polystyrene, and this presents a challenge for the Biosphere's team.
Even so, biodegradable packaging which can be produced without burning fossil fuels, such as the petroleum used in plastics manufacture, may have a bright future bearing in mind the growing calls among both consumers and some governments to cut carbon dioxide emissions and reduce waste.
The European Union recently proposed taxes on packaging waste produced by companies and only in the last few weeks Dutch packaging supplier, RPC Bebo Nederland, has launched a range of biodegradable containers using polyactide material which is processed from renewable energy sources such as corn.
The US government has become notorious for its rejection of environmental decline but Helou said a number of large food and bakery companies in the country were interested in PPM100, including Sara Lee and Amy's Kitchen.
Helou said that Biosphere was preparing to use its own production facilities in Malaysia and was developing another in the US, while the company also wants to promote its baking pan and PPM100 material generally in Europe.
"We have completed stringent independent laboratory testing in the US and Canada and our products are currently being reviewed by the Biodegradable Products Institute and we expect certification to be given soon," said Helou.
Biosphere is also working on another similar material called PPM200, which has been designed to meet high moisture and steam generating conditions such as noodle bowls, coffee cups, soup bowls, frozen prepared meals, and other hot or cold moisture food products such as meat trays.