A day after Saji Varghese, an associate professor of English at Christ university in Bengaluru had a conversation with a guest from the Netherlands on the impact of single-use plastic, his eyes fell on a dried coconut leaf in the university campus and an idea struck him. As he reveals, it was like an epiphany moment for him.

He believed it could be transformed into an environmentally beneficial substitute for plastic straws to have a "good impact" on the environment, something he had always considered.

Saji then started his research with dried coconut leaflets. He observed a shine forming on the leaves' surface as he pressure-steamed the dried coconut leaves for his research. He found that naturally dried leaves had a natural wax that, when steamed, rose to the surface. Saji realized that the wax might give the suggested straws the anti-fungal and hydrophobic qualities that are essential in drinking straws.

Saji finally established Sunbird Straws to produce drinking straws derived from naturally dried coconut leaves in 2020, three years after he had originally planned to. According to Saji, technological innovation has assisted the team in streamlining its production process. The team created a conveyor system that can produce one straw every 1.5 seconds as opposed to the previous requirement of 45 seconds for each straw.

According to Saji, 86 women are engaged during both the pre-production and production phases, giving them yearlong income prospects. The company plans to increase manufacturing to 10 lakh straws each day and hire 1,000 women over the next three years. Additionally, it is looking at joint ventures abroad and developing other dried leaf products.