The new BDFS plant will manufacture an entirely new line of products, based on the equipment’s ability to expand plant and vegetable starches in a manner similar to that used in the production of Styrofoam. Furthermore, all materials will be sourced in the U.S.A., naturally abundant, sustainably grown – or all the above. In addition, the shelf-stable products will degrade very rapidly across a wide range of composting processes.
Kevin Duffy, President of BDFS, described the installation as one of incredible efficiencies. “The amount of research that went into building the production machinery is phenomenal, and each phase of the process was scrutinized in an effort to maximize its use of energy and materials.” For example, waste steam (water) and trimmed scrap (inert fiber) are recycled and re-used onsite. Duffy added that “The Life Cycle carbon footprint of this technology is significantly lower than any BDFS product sold to date. The synergy of materials sourced in America, the American-made equipment, and a Central U.S. distribution location is an accomplishment we’re quite proud of.”
Historically, BDFS has been exclusively involved in the manufacture of disposable containers specific to the Food & Beverage industry. “Bakeries in particular love the high-heat tolerance of our new substrate” said Mr. Duffy.
However, he indicated that the compartmentalized production lines offer great flexibility in the range of formulations, mold shapes, and finishes they can generate. “Manufacturers in several non-food industries have inquired about the new substrate, because the effort to replace expanded polystyrene with a more sustainable alternative becomes more pervasive every day.”
Initial production runs are set to commence in January of 2012.
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Biodegradable Food Service LLC is based in Sunriver, Oregon.
The company has specialized in the manufacture of responsible, earth-friendly packaging and single-use tableware for the foodservice industry sector.