No plastic, only coconut leaves: Bengaluru Christ University professor builds Rs 70 crore business by making eco-friendly straws, products are exported to 25 countries

Plastic products leach hazardous microplastics and toxic chemicals like phthalates into ecosystems, severely contaminating soil and water systems. Despite severe environmental persistence and bioaccumulation in human food chains, plastic dominates everyday consumer items due to its ultra-low manufacturing cost, durability, and unmatched packaging convenience. But a professor from Christ University in Bengaluru has found an alternative. He has built a Rs 70-crore business by making sustainable products, especially eco-friendly straws from coconut leaves, which are now being imported to over 25 countries.

Prof Saji Varghese, the man behind the innovation, is not only an English professor at the reputed Christ University, but he also holds a PhD in English. However, it is his work in sustainability that has earned him praise both in India and abroad. Varghese’s brand is called Sunbird Straws.

Bengaluru professor’s chance discovery sparks sustainable idea

Varghese’s journey began in 2017, when he was walking home after taking classes. Suddenly, he spotted a dry coconut leaf on the ground, a part of which had naturally coiled into the shape of a straw. Struck by curiosity, he took the leaf to a lab and steamed it under high pressure. Surprisingly, the heat brought out a shiny surface on the leaf, which sparked the idea of making plastic-free straws.


Soon, Varghese found himself experimenting with food-grade glue utilising various techniques, and finally, after months of trials, he succeeded. Varghese managed to develop a multi-layered, durable, and anti-fungal straw which could stay firm in water for over 6 hours, having a shelf life of more than a year. In 2018, Varghese achieved the milestone of receiving the patent. In a conversation with The Indian Express, Varghese revealed that 600 straws could be made from one coconut frond, which could further be used for 6 months.

From village units to global exports

Samples of some of the straws, with a 3- 13 mm diameter, were sent to countries like Malaysia, the USA, the UK, Canada, Australia, the Philippines, Spain and Germany, where the authorities approved the product and also placed orders for a total of 18 million straws. Eventually, Varghese set up 3 units in villages of Madurai, Kasargod and Tuticorin, where rural women were employed to collect dry fronds and make the straws with machines.

To prepare the straws, the coconut leaves undergo a 3-step cleaning process, followed by scraping and rolling. The straws are finally produced by in-house machinery so that they stay hygienic. Apart from that, the company uses food-grade adhesive to make the products free of chemicals. Varghese’s eco-friendly straws have received several awards, including the Swadeshi Startup Award 2018 from IIT Delhi, the Swiss Re Shine Entrepreneur Award, and the Climate Launchpad Award 2018 for social impact from Scotland.