Former Apple exec turns 500 years of ocean waste into backyard compost

Expanded Polystyrene (EPS) has long been a go-to material for electronics and automotive packaging due to its lightweight and protective properties. However, EPS takes up to 500 years to degrade and contributes to 11 million metric tons of plastic in the ocean annually.

With less than 10% of EPS recycled due to contamination and high transport costs, industries struggle to find sustainable alternatives. Major states in the US, including California and New York, have implemented bans on EPS food containers, further increasing the pressure for eco-friendly solutions.

GreyB’s research identified a California startup, Blue Lake Packaging, that developed a fiber-based agricultural waste alternative. This material matches EPS in strength and decomposes naturally in backyard compost.

We spoke with Ying Liu, founder of Blue Lake Packaging and a former Apple Executive, to explore how their innovation reshapes packaging for heavy-duty use. This interview is part of GreyB’s Scouted series. In this series, we spotlight innovative startups and speak to their founders about how their solutions can revolutionize the industry by solving problems. You can find all those interviews here.

I believe the next generation deserves better solutions for the environment. Everything we do is about leaving a cleaner, more sustainable world for the future.

– Ying Liu

Want to know how Blue Lake Packaging is doing it? See for yourself.

Overview: Blue Lake Packaging’s eco-friendly fiber-based packaging replaces EPS in protective applications

Blue Lake Packaging develops sustainable alternatives to plastic packaging, using fiber-based cellulose materials sourced from agricultural waste, bamboo, and wood pulp. Their innovations include biodegradable and recyclable fiber foam for protective packaging. They also offer plastic-free tape and a dispenser made with cellulose film and molded fiber technology. These solutions replace EPS and bubble wrap, offering environmentally friendly backyard compostable or paper recyclable options.

Blue Lake’s modular manufacturing processes are focused on scalability and cost-effectiveness and enable global deployment while meeting diverse performance needs. Their versatile materials support applications in electronics, furniture, and more, extending beyond packaging to products like office supplies and pet items.

Highlights from the conversation

You mentioned using cellulose-based and natural fibers for your packaging. Could you detail your sourcing methods and the process of utilizing these materials?

Ying: At Blue Lake Packaging, we use a variety of plant-based fibers, including wood pulp, sugarcane bagasse, bamboo, and agricultural waste, focusing on their properties rather than origin. Our “from nature to nature” approach ensures materials can be recycled with paper or composted, naturally biodegrading without harm.

We carefully evaluate fiber characteristics like strength and compressibility, using bio-based additives and tailored manufacturing techniques to meet product needs. We maintain a sustainable and adaptable supply for our mission by sourcing globally and leveraging agricultural byproducts.

Do you envision applications for Blue Lake’s solutions in the food and beverage industry?

Ying: We see significant food and beverage industry interest in sustainable packaging solutions. Still, our current focus is on areas where we can add the most value, such as protective packaging for electronics, furniture, and other industries. We are exploring specific coatings and solutions for certain food applications. However, we do not prioritize items like bio-based films for paper cups or snack bags, as many solutions already exist.

What technological or logistical challenges has Blue Lake faced in developing and scaling your solutions? Could you share specific examples of how your team addressed them?

Ying: Blue Lake faced challenges from scratch, as fiber-based cushioning solutions were limited. We overcame this by conducting extensive experiments to prove concepts and iterating designs. Scaling was another hurdle, requiring the development of modular, flexible manufacturing equipment to ensure cost competitiveness and global deployment.

We also addressed variability in natural fibers by testing and fine-tuning formulations and manufacturing processes to maintain consistent performance. These efforts have enabled us to scale effectively while delivering sustainable and adaptable solutions.

How straightforward can companies integrate your solutions into their supply chains? Do they work with you for raw materials, or do you provide fully developed products?

Ying: Integrating our solutions into supply chains is designed to be flexible and collaborative. Companies can work with us in several ways:

1. Consulting Services: We evaluate their current packaging systems and recommend sustainable alternatives, even if Blue Lake doesn’t directly supply the materials.
2. Fully Developed Products: We offer end-to-end solutions, from design to delivery, tailoring our products to meet specific performance, cost, and sustainability targets.
3. Manufacturing Partnerships: In the future, we plan to provide equipment and technology to packaging companies, enabling them to produce sustainable materials using our methods. This approach helps scale adoption globally and accelerates the transition to sustainable packaging.

Companies can choose ready-to-use solutions or integrate our technology into their operations. We strive to make the process seamless and effective.

Meet our Interviewer – Shabaz Khan, Marketing Manager at GreyB

Looking for similar sustainable packaging startups for the electronics and automotive industries, or have a startup you’d like to know about in detail? Connect with our experts.