New research project explores mycelium-based alternative to polystyrene packaging

A new research partnership involving the University of Bath, University of Nottingham, Swansea University and Magical Mushroom Company (MMC) aims to develop mycelium-based protective packaging as a biodegradable alternative to expanded polystyrene (EPS).

The project has received £800,000 in funding from the Engineering and Physical Sciences Research Council (EPSRC) through its Materials Innovation Partnerships Programme. With additional contributions from MMC, including technical expertise and access to manufacturing facilities, the total project value is £1.4 million.

The research will focus on developing lightweight, durable and water-resistant packaging materials that can be manufactured consistently at an industrial scale.

Mycelium, the root-like network of fungal filaments, can bind agricultural plant fibres together as it grows, creating moulded composite materials. Researchers will examine how fungal biology, feedstock structure and processing conditions influence the strength, weight and consistency of these materials.

The partnership will also investigate fluorine-free surface treatments to improve moisture resistance, durability and resistance to biological deterioration during storage, while maintaining the material's biodegradability.

Further testing will assess how the internal structure of mycelium composites affects impact absorption, resistance to repeated loading and performance in humid conditions. The findings will help determine their suitability for different protective and transit packaging applications.

EPS is widely used for cushioning and impact protection but presents environmental challenges due to its petrochemical origins, limited recyclability and potential to break down into microplastics.

Sustainable packaging has to prove itself beyond the brochure and AI renders. At Magical Mushroom Company®, we operate three facilities, including two in Nottingham, supply established commercial customers and put our packaging through performance testing.

Paul Gilligan, Founder and CEO of Magical Mushroom Company®.

The project builds on MMC's existing commercial production of Mushroom® Packaging at its Beeston facility in Nottinghamshire, where the company already manufactures mycelium-based packaging for customers including Raymarine.

The research findings will support further material development and help identify opportunities to expand the commercial use of mycelium-based protective packaging.