From Waste to Wonder: Dried Coconut Leaves Replace Millions of Plastic Straws, Empowering Rural Women in India

When Saji Varghese set out on his early morning walk in October 2017, little did he know that he would make a discovery capable of reducing plastic waste and aiding rural Indian women.

Today, his coconut straws called 'Sunbird' are gaining global recognition as the social enterprise he co-founded strives to meet the increasing national and international demand, bringing Saji’s dream of eliminating plastic straws one step closer to reality.

Saji, an associate professor of English at Christ University in Bengaluru, has always harbored an interest in sustainable, innovative practices with a social impact. During an October 2017 walk on the university grounds, he stumbled upon a dried and curled coconut leaf. “It just happened; it struck me,” he recalls. Experimenting with the leaf, he discovered that when soaked, it became leathery, and steaming it revealed a nice shine. “That is when I realized that coconut leaves have their own epicuticular wax, which is a perfect property for a straw,” he explained.

Chirag M G, a Master’s graduate in astronautics and space engineering, met Saji while studying at the University and enthusiastically started working on machines that could roll the leaves into straws. In 2020, they co-founded Brown Reed Agri Waste Innovations and worked on refining the straws to their current multilayered iteration and manufacturing.

Growing Production, Increasing Efficiency and Profit for Women

Sunbird straws are biodegradable and exist in four standard sizes for all kinds of cold drinks, from cocktail to shakes, smoothies and Boba tea. Customization for any diameter is available on demand.

The company sources leaves from coconut-growing regions such as Karnataka, Kerala and Tamil Nadu. These leaves undergo steaming, cutting into different lengths, and are then processed and rolled into straws using machines operated by trained women at production centers in Mysuru (Karnataka), Kasaragod (Kerala) and Tuticorin (Tamil Nadu). Following UV sterilization, the straws are packaged and dispatched.

Recently, Chirag and his team developed an integrated conveyor system reducing production time from 45 seconds to 1 second, to be implemented across all manufacturing centers. This new system lessens fatigue for operators, and by reducing costs, increases profit for women. Daily production currently stands at 10,000 straws a day but is projected to reach 300,000.

Close to a hundred women are currently employed, but Saji explained that within the next year, he expects the company can recruit between 400 and 500 women. Abundant coconut resources fuel the team's dream of expanding the social enterprise, supporting thousands of women across India and neighboring countries.

Serving the Environment, Reducing Plastic Use

Sunbird straws are making use of coconut leaves which used to be agricultural waste, providing farmers with an additional income.

Chirag estimates that Sunbird straws have replaced some 2 million straws and saved 10 tons of coconut leaves from being burned as waste. The company is also making use of straws that did not pass quality control by doing some vertical innovation and turn them into pens known as “Scribbles.”

A Trademark that Tells a Story, Patents to Secure invention

The co-founders chose "Sunbird" as a fitting brand name, drawing inspiration from the small bird known for its naturally shiny feathers and efficient bill for sipping nectar. Saji emphasized, "Our straws also have a natural shine, and we can customize them for any beverage." Chirag added, "Every straw we sell has a unique story."

The machines and process are patented in India, with recent filings at the European Patent Office and the United States Patent and Trademark Office for the straws and machines. A patent is also underway for the new integrated system.

Chirag, a participant in WIPO's IP mentoring session in Mongolia, shared insights from Brown Reed Agri Waste Innovations' success in the WIPO-supported Youth Ecopreneur Awards. The company, supported by WIPO IP Management Clinics, is refining its patent strategy.

Operating on a B2B model, Brown Reed Agri Waste Innovations supplies straws to premium hotels and resto-bars in India. Orders from different parts of the world are pouring in, but the production is currently the limiting factor. “Even meeting the local market is a challenge, but we are positive that we will be able to scale our production and capture both domestic and international market” Chirag said, “but the demand currently is huge!”

The co-founders aim to produce 1,000,000 straws per day and employ 1,000 women within the next three years.