Our Trip to Shellworks

How bacteria make plastic-free packaging

Our team visited Shellworks' facilities as part of our ongoing collaboration with the sustainable packaging company. The visit offered an insightful look into their innovative processes, where biological intelligence meets sustainable design.

Our visit began in their laboratory—the core of their operation. Here, we observed the relationship between carefully cultivated bacterial strains and material development. The team demonstrated how different bacterial strains produce materials with distinctly varied properties in a fermentation process, from flexible to structurally rigid compositions, each with unique tactile qualities.

Insiya Jafferjee, the founder of Shellworks, articulated this natural alchemy perfectly: "If nature had made plastics, this would be it." Shellworks' approach reimagines what materials can be when developed in partnership with natural processes.

The Shellworks team explained their bacterial fermentation process, which is similar to cheese-making. In this process, bacteria transforms organic inputs into pellets of their innovative material, Vivomer. The result is a substance that performs remarkably like conventional plastic while maintaining complete compostability.

What distinguishes Shellworks' approach is its commitment to practical implementation. Their Vivomer material has been meticulously developed to integrate with existing plastic manufacturing infrastructure, allowing for a seamless transition to sustainable packaging solutions without requiring industrial reinvestment. 

Our conversations led to meaningful dialogue regarding the critical importance of accessible communication when introducing innovative materials to the marketplace. We discussed the necessity of educating both existing consumers and future adopters about these new alternatives, recognising that even the most sustainable solutions require thoughtful integration into everyday practices.

A significant moment of our visit was examining their composting facility, where we saw our own previous packaging being metabolised by microorganisms. This completed circle demonstrated Vivomer’s capacity to break down in domestic composting environments within twelve months. This represents a fundamental shift in packaging philosophy—one where consumers need not navigate complex recycling systems, as the material naturally returns to the earth through simple composting practices.

We concluded our visit with a thoughtful conversation with Insiya, whose vision has transformed the packaging landscape. She shared reflections on Shellworks' evolution, from their initial material developments to our conversations with the FKA Haeckels team to develop a vegan solution five years ago, to their latest packaging offerings. 

Insiya left us with a compelling thought that resonates deeply with our philosophy: 

"If you have an opportunity to do something impactful in life, take it.”

We invite you to stay tuned for our upcoming interview with Insiya, where we will further explore Shellworks' journey, challenges, and future innovations in sustainable material development.

Our five-year partnership with Shellworks represents our commitment to materials that honour both human experience and environmental integrity. Their Vivomer material exemplifies how innovation can seamlessly unite sustainability with practicality, creating solutions that are as functionally considered as they are ecologically responsible.