Chippewa Valley Times

Disposable coffee cups contribute significantly to sustainability issues, with over 40 billion discarded annually in the U.S. alone. These cups are typically non-recyclable and take extensive time to decompose, posing environmental challenges.

GaeaStar, a startup based in San Francisco, is addressing this issue by producing eco-friendly disposable coffee cups made from clay with a liquid-proof glaze. These cups can be reused or easily decomposed when disposed of.

To enhance production efficiency, GaeaStar collaborated with students from UW-Stout’s Robert F. Cervenka School of Engineering. A team of students developed a new machine to expedite the cup glazing process for GaeaStar, increasing its daily output fourfold.

The team created the GaeaStar-Cup Glazing Prototype, which performs a semiautomated fountain glaze application that ensures consistent coating without external residue. The prototype was presented on December 18 to GaeaStar officials and others involved.

Morgan Young expressed satisfaction with their achievement: “GaeaStar had trust in us that we could do this, and we are overwhelmed with what we’re delivering to them.” The machine can glaze ten cups per minute compared to the manual system's one cup per minute capacity.

Noah Pearson-Cater highlighted the importance of understanding the process before building: “A big part of it was all the testing we did. The company official realized that we were trying to understand the process before we began to build.”

Harrison Lin from GaeaStar stated: “It was a pleasure working with the team. I am very much looking forward to receiving the prototype.”

Other capstone projects completed included automation tasks for various companies like Antigo Zeon Wire and Colder Product Company Manufacturing. These projects received full financial support from sponsoring companies for equipment and materials.

One notable project involved developing an automatic assembly system for toys designed by first-graders at St. Paul’s School of Menomonie. This initiative was supported by the G.A. Taft Manufacturing Engineering Endowed Professorship awarded to Assistant Professor Kevin Dietsche.

The engineering capstone classes are led by faculty members including Assistant Professor Danny Bee and Senior Lecturer Glenn Bushendorf. Students employ stage gate-driven design methodologies and submit project documents for potential integration into manufacturing operations after presentations.

Graduates from these programs reported 100% employment rates and starting salaries exceeding $70,000 according to recent data.

UW-Stout’s Robert F. Cervenka School of Engineering offers several ABET-accredited programs alongside a master’s program in manufacturing engineering available both on campus and online.