QSR Compostable Packaging Rollout: 200 Outlets in 90 Days

This case study is anonymized at the customer’s request. Volumes, dates, and outcomes are accurate; identifying details are generalized.

The challenge

A regional Indian QSR chain operating 200 outlets across five states, with daily takeaway volumes of approximately 80,000 containers, faced an existential supply-chain decision in mid-2024. India’s Single-Use Plastic ban (in force since 2022) had been extended to cover additional categories that included their primary 8×8 plastic clamshell SKU. Enforcement against non-compliant operators was tightening; brand reputation and operating licences were both at risk.

The chain’s procurement team had four constraints:

• Replacement SKU had to match existing operational dimensions (8×8 with internal compartments to hold burger + sides)
• Total landed cost increase had to stay below 8% to remain absorbable
• Rollout had to complete within 90 days to meet the enforcement deadline
• FSSAI and audit-ready documentation needed across all 200 outlets

Why bagasse, why Ecofy

The procurement team evaluated five suppliers across two materials (bagasse molded fiber and PLA-composite). Ecofy was selected on three factors:

1. BRCGS A+ certification: only one of the five suppliers held A+ unannounced grade. This eliminated the risk of facility-condition surprises during scaling.
2. FCL lead time: Ecofy committed to first FCL delivery within 4 weeks of PO; competitors quoted 6-8 weeks.
3. In-house custom tooling: the chain wanted custom embossing of its logo on the clamshell lid; Ecofy completed tooling within 6 weeks.

The 90-day rollout playbook

Days 1-14: Pilot and tooling

• Sample order (1,000 pieces, standard 8×8 3CP white clamshell) shipped within 5 days
• Pilot rollout in 5 outlets in one city; operational feedback collected over 7 days
• Custom tooling for embossed logo SKU initiated in parallel

Days 15-30: First FCL and 50-outlet rollout

• First FCL (~120,000 pieces of standard SKU) shipped from JNPT to the chain’s central warehouse
• Distribution to 50 outlets across two states (the chain’s strongest performance markets)
• Operational signoff: leak-resistance, microwave performance, stack-friendliness all matched or exceeded the previous plastic SKU

Days 31-60: Custom-tooled SKU + 100-outlet expansion

• Custom-embossed SKU production completed; second FCL with the branded variant
• Expansion to 100 additional outlets across the remaining three states
• Branding feedback from outlet managers and franchisees: positive, especially the visible “compostable” embossing

Days 61-90: Final rollout and inventory wind-down

• Remaining 50 outlets switched to bagasse SKU; old plastic inventory drawn down to zero
• FSSAI compliance documentation sent to each outlet for licence-renewal cycles
• BRCGS A+ certificate, FDA documentation, and Sedex audit report sent to chain HQ for ESG reporting

The results

Metric	Before (Plastic)	After (Bagasse)
Unit cost (₹ / piece)	₹4.20	₹4.55 (+8.3%)
SUP-ban compliance	Non-compliant	Compliant
Annual SUP-ban penalty exposure	~₹4.2 Crore (estimated)	₹0
Customer complaints / 1000 orders	2.1	1.8
Brand-perception lift (post-rollout survey)	N/A	+12 points net favourability

Net economic outcome: the 8.3% unit-cost increase was more than offset by avoiding the ~₹4.2 Crore in estimated SUP-ban penalty exposure and the brand-perception improvement. The chain also gained the ability to compete on ESG-reporting credentials with national chains it had previously trailed.

Lessons for similar QSR rollouts

1. Pilot in 3-5 outlets first, even on a tight timeline. The two days of operational feedback caught a stack-height issue with the custom embossing that would have required production changes if rolled out to all 200 outlets first.
2. Run standard and custom-tooled SKUs in parallel. Standard SKU rollout in weeks 2-4 bought time for custom tooling without missing the deadline.
3. Distribute compliance documentation to every outlet, not just HQ. Local FSSAI inspectors visit outlets, not the chain’s corporate office. Outlet managers needed local copies of certificates.
4. Brief franchisees on the cost increase before they see it on POs. The 8% unit-cost increase needed franchise-side communication; without it, complaints would have driven rollout friction.
5. Use the rollout as a brand moment. The chain ran in-outlet signage about the switch (“Now serving in 100% compostable packaging”) which generated positive customer feedback at minimal cost.