At BioPak, we know that some of the most interesting packaging challenges come from the formats people rarely stop to think about. Everest Ice Cream brought us one of those challenges: a small 4oz ice cream tub designed for airline service, traditionally made with a plastic tub, a plastic lid, and a plastic spoon embedded into the lid. Everest wanted to move away from plastic, but the replacement had to work just as hard as the original format.
That meant developing a paper-based solution that could perform in a highly specialised production environment, preserve the convenience of the spoon-in-lid experience, and stand up to blast freezing and long-term frozen storage. It was a technically demanding brief — and exactly the kind of problem-solving collaboration we love.
A Complex Format with a Clear Goal
Everest is a Melbourne-based ice cream supplier serving airlines and food brands. For this application, they were using a compact single-serve tub where consistency, convenience, and packing efficiency are essential. The existing format worked operationally, but relied entirely on plastic.
Everest came to BioPak with a clear goal: transition to a more responsible material solution while maintaining performance. This is where paper-based packaging, made from responsibly sourced materials like FSC™ certified paper, plays an important role. FSC™ certification ensures that the wood used to create paper packaging comes from responsibly managed forests that support biodiversity, communities, and long-term environmental outcomes.
This was not a simple material swap. The pack needed to protect the product, work in an automated line, and retain the built-in spoon functionality that made it so practical for airline use.
Built for Blast Freezing
One of the most important parts of this project was understanding Everest’s production process. The ice cream is filled while still soft and creamy, then blast frozen within minutes. From there, the tubs are packed, palletised, and stored in freezer systems before being supplied to airlines, allowing for a shelf life of up to a year.
For BioPak, that raised a key question: would a paper-based format perform under these conditions? By working closely with Everest and observing their process, we developed a solution that could withstand freezing, storage, and handling without compromising integrity.
Replacing Plastic Without Losing Convenience
The most distinctive feature of the original pack was the spoon embedded in the lid — something we needed to retain.
Our solution was a paper lid with a reinforcement disc that securely holds a wooden spoon in place. This design reimagines the plastic spoon-in-lid system using renewable materials, including FSC™ certified paper and birchwood sourced from responsibly managed forests. FSC™ certified birchwood ensures the material is sourced under strict environmental and social standards while supporting a move away from conventional plastic packaging.
A cut-out in the lid structure allows visibility of the spoon while keeping it secure during packing and transport. The result is a familiar user experience, delivered through a redesigned material system.
In December 2025, Everest ran trials using the new tubs through their production line. The packaging performed well, running smoothly through machinery and maintaining its structure throughout the process.
This confirmed that the solution was not only viable in theory, but workable at scale. Everest moved forward with production, marking an important step in transitioning this format away from plastic.
A Collaboration Shaped by Real-World Packaging Challenges
What makes this project compelling is how it reflects real-world packaging innovation. The challenge wasn’t just about materials; it was about performance, process, and practicality.
By combining structural design, material innovation, and collaboration with Everest’s team, BioPak delivered a solution that balances convenience, performance, and responsible sourcing.
It’s a reminder that meaningful progress often comes from solving complex, everyday packaging problems, and showing that paper and wood can perform in applications where plastic once dominated.