Leafline Insights & Stories

PFAS regulations are accelerating across North America, and the operational impact on foodservice packaging is real. Operators need materials that handle heat, liquids, oils, and sauces — without leaving behind harmful chemicals or microplastics.

Bagasse molded fiber is now emerging as the leading replacement for petroleum-based disposables. Made from the residual pulp of sugarcane after juice extraction, bagasse is an agricultural by-product that would otherwise be burned or wasted.

When engineered through modern thermoforming, bagasse becomes a strong, compostable, heat-resistant material that performs exceptionally across the entire foodservice spectrum — from quick-serve to catering to institutional dining.

Why bagasse beats PFAS-lined plastics

Zero PFAS by design — No forever chemicals, no fluorination, no coating.

Heat & liquid resistance — Holds curries, noodles, and steaming meals without softening.

Rigid structural strength — In many formats, stronger than traditional paper plates.

Compostable — Breaks down in industrial facilities within weeks.

Closed-loop manufacturing — Uses a renewable waste stream instead of petroleum.

Industries switching fastest

Quick-serve & fast casual

Stadiums & concession arenas

Healthcare & senior living

University dining

Catering and events

Leafline Eco is working with operators across the US and Canada to replace millions of pounds of PFAS-based packaging every month. As composting access increases, the environmental impact compounds rapidly.

Clamshell containers are some of the most demanding products in foodservice packaging. They must withstand temperature shifts, condensation, stacking, transport, and sauces without leaking or warping.

Leafline Eco’s engineering team designed our clamshell line with three goals:

1. Real structural rigidity

Our product surface geometry uses ribbing and tapered walls that increase stiffness without adding unnecessary thickness. This makes the clamshell feel premium while keeping material usage optimized.

2. Liquid + oil defense with ZERO coatings

We worked through dozens of forming pressure and drying profiles to create a natural barrier using only fiber — no coatings, no lamination, no chemistry.

This ensures true PFAS-free compostability.

3. Compatibility with modern delivery operations

We tested our clamshells in:

High-moisture meals

Saucy and oily items

30–40 minute delivery windows

Stack loads used in catering operations

The result is a clamshell that rivals plastic in function, while outperforming it in sustainability.

New formats launching in 2025

6-inch snack

8-inch 1-compartment

8-inch 3-compartment

9-inch entrée

Hingeless lid options for compact stacking

Leafline Eco continues to invest in tooling and forming innovation to push the boundaries of sustainable packaging performance.

When a regional fast-casual group approached Leafline Eco, they faced a challenge seen across today’s foodservice sector:

“We need packaging that performs like plastic — without the PFAS, the waste, or the customer backlash.”

Within 90 days of switching to Leafline Eco molded-fiber packaging, the chain achieved measurable improvements across sustainability and operations.

Key Results
• 42% reduction in total plastic packaging use

Transitioning their entrée bowls, lids, and clamshells removed more than 7.1 tons of petroleum-based plastics within the first quarter.

• 29% fewer customer complaints

Particularly around “lid popping,” container warping, and plastic waste concerns.

• 18% faster packing line throughput

Lightweight molded-fiber bowls reduced handling time and improved consistency.

• Improved sustainability branding

Customers frequently mentioned the compostable fiber packaging in reviews and feedback channels — creating brand goodwill without extra marketing spend.

Why they stayed with Leafline Eco

The operator cited:

Reliable performance with hot meals

Strong lids that “snap” properly

Compostable, PFAS-free material

Consistent supply and inventory planning

Ability to scale as new locations opened

This partnership is now expanding to 17 more locations in 2025.