Episode 5: Rhythm 108

In this episode, we dive into the complexities of creating center-filled biscuits—an innovative, delicious product that ticks all the right boxes. Not only are they 100% plastic-free, but they are also gluten-free, organic, and vegan, with 21% less sugar than other biscuits in their category. Tune in as we discuss everything from packaging to shelf life, product behavior during tests, and the potential for future improvements

The Packaging Puzzle: 100% Plastic-Free and Home Compostable

A key feature of this biscuit is its 100% plastic-free packaging. It’s home compostable, which is a significant step toward sustainability in the food industry. The packaging claims a one-year shelf life, but how does it perform under various conditions? Our team conducted several tests to assess hermeticity (the ability of the packaging to be airtight) and overall quality, particularly focusing on the “fin seal” of the packaging, which appeared to be a weak point during our analysis.

Understanding Hermeticity and Shelf Life

We tested multiple packages using Exos, including leak tests and burst tests, to see how well the packaging could protect the product over time. Our results showed consistency across most samples, with only minor issues in a few cases. Interestingly, the fin seal—where the package is closed—often popped open, but without breaking the packaging material itself. This led us to believe there is room for improvement in the sealing process.

The Product Inside: Liquid Filling and Changing Texture

Inside the package is a biscuit with a center of liquid chocolate or hazelnut cocoa paste. While this filling promises to be liquid, we found that the texture had already begun to harden, raising questions about the product’s longevity and moisture content. We discussed the challenges of maintaining the right texture, especially given the biscuit’s gluten-free, vegan, and reduced-sugar formulation.

The Future of Sustainable Packaging: Opportunities and Challenges

The discussion also touched on the broader implications of using biodegradable materials in packaging. While the paper-based outer layer is home compostable, there are still questions about the sealing material and its actual compostability. The rise of such innovations highlights the food industry's efforts to move away from plastics, but the cost and performance still need refinement to compete with conventional packaging.

Conclusion

As we conclude this episode, we’re left with a sense of optimism for the future of sustainable packaging and healthier, innovative products like these biscuits. While there are still challenges to overcome—such as improving the fin seal and maintaining the product’s liquid texture—the progress made so far is impressive. We look forward to seeing how this space evolves and what new solutions emerge.