Packaging Corner: Mushrooms form basis of protective packaging

While there’s been ongoing interest in finding sustainable, molded-cushion packaging solutions among corporations across a variety of industries, it would be a strange trip indeed to think that any would willingly pay more for product protection or accept a decrease in performance.

So when Sealed Air unveiled Restore Mushroom Packaging last year—offered as an alternative to non-recyclable, molded expanded polystyrene (EPS) foam packaging—the company felt it had hit “the sustainability trifecta,” says Tim McInerney, sustainable solutions business manager.

“Restore Mushroom Packaging is made from rapidly renewable raw materials that are all natural and completely home compostable,” McInerney says. “Plus, it protects products through the shipping cycle just as well as traditional materials, and it doesn’t come with a price penalty. It’s affordable for companies to use in their operation.”

Restore uses mycelium. Not familiar with that ingredient? It’s the vegetative part of a fungus, commonly found in mushroom roots. And, says McInerney, it grows into seriously strong packaging.

The mycelium is mixed with regionally sourced, non-food agricultural byproducts, such as corn stalks that would otherwise be left in the field after harvest. The resulting mixture fills custom, thermoformed trays. The company engineers the forms to create the custom protective packaging shapes that best protect the product during handling.

“The mycelium grows and binds all the other natural ingredients together into a solid cushion in the shape of the mold,” McInerney says. “Our engineers design, develop and test the cushions and their construction in accordance with International Safe Transit Association protocols and standards. This process helps us determine the best way to maximize the material’s performance and while using less of it—which is another goal for sustainability.”

The mixture grows into the final shape in just a few days without added heat, light or pressure. Once it reaches the desired form, a low-energy, low-heat treatment process is applied to cease the material’s growth. In use, Restore Mushroom Packaging is completely inert, says McInerney.

“It behaves much like corrugated packaging—except that it’s highly flame-retardant as a natural property of the material,” he adds. “And, because the material naturally has anti-static properties, it’s ideal for computers and electronics.”

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