Manufacturing Process

Sourcing

At Biogreen, we employ a community-based approach to procure raw materials for Bio Green Plates. There are three methods through which we obtain the areca palm trees.

Between October and May, farmers collect the leaves shed by the palm trees, which Biogreen then procures directly from their doorstep.
The majority of Biogreen’s raw materials are sourced from four districts in Karnataka. We conduct large-scale auctions and purchase leaves from entire villages, which are then transported to our manufacturing centers.
Farmers collect and deliver the leaves to the nearest of our 30 collection centers located in the hinterland of Karnataka, or directly to the manufacturing center.

Supported by our network of farmers, we maintain a stock of 30 million premium quality leaves across 90 Biogreen and micropreneur community sites. This stock is crucial for ensuring a continuous supply to our customers.

Hydro-Pressure Cleaning & Sterilizing

The gathered areca palm leaves undergo a meticulous cleaning process. We wash them with high-pressure water to ensure they are free of sand and grit particles. After washing, the leaves are dried for seven hours before being pressed in a state-of-the-art hydraulic heavy-duty machine. To achieve the desired shape, we use CNC dyes. During this process, the palm leaves are subjected to 200 degrees Celsius of heat, which sterilizes the tableware.

Edging & UV Treatment

After hydro-pressure cleaning, the tableware is sorted, and our quality inspection team removes any defective products. The selected plates are then edged with a nosing machine to ensure a smooth finish. A high-pressure air cleaning process follows, removing any dust particles that may have accumulated during nosing. For added safety, Ecodyne Tableware undergoes UV sterilization to ensure optimal hygiene.

As India’s largest manufacturer and exporter of disposable areca leaf tableware, we adhere to international quality standards. Our manufacturing process meets the hygiene regulations set by the USA and Europe. Ecodyne Tableware is 100% chemical and additive-free, and its carbon footprint is significantly lower compared to alternative products on the market.

The Packing Process

Biogreen employs a standardized packing process designed for bulk consumption. We use a 5-ply food-grade corrugated box that accommodates 4 units of 25 shrink-wrapped pieces using 19-micron poly-olefin, totaling 100 tableware pieces per carton. Each of the 25-piece shrink-wraps is adorned with a multicolored sticker, while the corrugated carton is labeled with a customized marking according to customer specifications.

Additionally, we offer BioGreen Plates for retail consumption, catering to individuals and homeowners. Our standard retail packaging includes 10 pieces of shrink-wrapped tableware, with customization options available to align with your company’s brand identity, upon request and at a pre-discussed cost.

Quality Assurance Process & Testing

At Biogreen, we oversee the quality of Biogreen Plates throughout the entire process, from sourcing to packing. Only products that meet our rigorous quality management standards are delivered to our customers.

Our quality assurance process consists of seven stages:

Leaf Selection – We exclusively select premium-quality leaves in excellent condition for Biogreen Plates.
Washing – We utilize hydro pressure to cleanse the leaves of any sand and grit particles.
Before processing –Our team carefully rechecks the cleaned leaves to remove any faulty ones.
After pressing –Ecodyne Tableware undergoes sterilization at 200 degrees Celsius. Any defective pieces are identified and removed at this stage.
Edging and trimming – Following the edging and trimming process, we meticulously inspect the products for any deformities or raw edges.
Scrubbing and UV radiation – Once the products are prepared, we give each piece a final scrub and sterilize them using a UV radiation conveyor belt.
Pre-packing and delivery – Before the final packing, our team conducts a final inspection to ensure each product meets the standards required for use by the end consumer.

Biogreen conducts regular quality tests every few months to ensure our products meet the standards expected by the end consumer. We evaluate product quality to ensure that food served in Biogreen Plates remains unaffected.