NantBioRenewables is scaling up its US manufacturing footprint with a major expansion at its Gadsden, Alabama facility, boosting production capacity, materials innovation, and domestic supply chain capabilities for food service and packaging markets.
The company, known for its Wave Ware renewable foodservice product line, said the expanded site significantly broadens its ability to work across multiple material platforms—including polypropylene (PP), polyethylene (PE), and certified compostable bioplastics—while also increasing thermoforming output and in-house resin development.
The move is aimed at meeting rising demand from foodservice operators, consumer packaged goods (CPG) brands, and specialty packaging customers seeking faster lead times, tighter quality control, and reduced reliance on overseas manufacturing.
“Our customers want performance, compliance, and reliability and they want it without the long lead times and variability that come with offshore production,” said Kenn Budlong, COO and Chief Engineering Officer.
“By manufacturing in Alabama, we can offer short lead times, customer-friendly MOQs, and a level of quality oversight that is difficult to achieve when production is happening 6,000 miles away.”
With the upgrade, NantBioRenewables now produces a wider range of foodservice disposables, including cold cup lids, bowl lids, trays, plates, bowls, and specialty items for high-volume operators.
The facility also supports both TÜV-certified home-compostable and BPI-certified commercially compostable materials, alongside traditional PP and PE production—giving customers more flexibility to align performance requirements with sustainability targets.
Company leaders say this multi-material approach is designed to help brands navigate tightening regulatory expectations while maintaining product durability and cost efficiency.
A key part of the expansion is enhanced R&D and materials science capability, including custom resin formulation and compounding across PP, PE, and compostable bioplastic platforms.
The company is also integrating its proprietary ocean calcium sand technology into material development to improve performance characteristics.
“We can custom formulate and compound resins across PP, PE, and compostable bioplastics using our proprietary ocean calcium sand,” said Dr. Andrey Tyuftin, Lead Research Chemist, Polymer Formulation & Compounding.
“It gives customers a sustainable, cost-effective performance boost without disrupting existing processing or mechanical requirements.”
Beyond foodservice products, the Gadsden facility now supports production of customizable tubular structures up to 10 mm in diameter, opening domestic manufacturing options for applications in food and beverage, cosmetics, nutraceuticals, and single-dose pharmaceuticals.
The capability is positioned as a US-based alternative to imported small-format packaging, with improved responsiveness and tighter production control.
By consolidating tooling, engineering, compounding, and production under one roof, the company says it can accelerate development timelines and improve supply chain resilience.
Benefits highlighted include shorter development cycles, rapid prototyping, faster iteration than overseas manufacturers, stable domestic supply, and consistent quality control.
“As regulations evolve and operators look for higher-performing alternatives to paper-based disposables, we’re focused on giving them materials that work — whether that’s PP, PE, or certified compostable bioplastics,” Budlong said.
“Manufacturing here in the US gives our customers the flexibility they need to stay compliant, maintain quality, and keep their supply chains stable.”
_256_275.jpg)
