A new research project will develop next-generation composites from mycelium, the root-like structure of a fungus, to create a sustainable alternative to expanded polystyrene (EPS) in protective and transit packaging.
University of Bath researchers are part of a project developing a new biodegradable product using mycelium that is lightweight, durable, water-resistant, and performs consistently under industrial manufacturing conditions.
Working in a consortium led by the University of Nottingham, alongside Swansea University and industrial partner Magical Mushroom Company® (MMC), the project has been awarded £800,000 by the Engineering and Physical Sciences Research Council (EPSRC) through its Materials Innovation Partnerships Programme. MMC will contribute technical expertise, staff time and and access manufacturing facilities to accelerate the move from laboratory research to commercial production, bringing the total project value to £1.4 M.
Associate Professor Dr Juliana Calabria-Holley, project Co-Lead and Co-Director of Bath's RENEW: Regenerative Design and Engineering for a Net Positive World Research Centre, said: "We're delighted to be part of My-Pack, a project creating a sustainable alternative to fossil fuel-derived packaging materials. By harnessing mycelium, a natural biodegradable polymer, My-Pack will develop high-performance, durable protective packaging for a range of consumer products.
“We will apply our expertise in the structure-property characterisation of porous biomaterials to optimise strength, water resistance, and long-term durability. Using nano-scale testing, electron microscopy, and cutting-edge sol-gel surface engineering, we will help ensure that next-generation mycelium packaging is not only sustainable, but also robust, resilient, and fit for real-world applications."
Biology, engineering and manufacturing
The research will investigate how fungal biology, material structure and surface treatments can improve packaging performance and extend its use as an alternative to expanded polystyrene (EPS).
The current product widely used is EPS packaging that offers lightweight cushioning and impact protection, but its persistence in the environment, potential to fragment into microplastics, limited recyclability and reliance on petrochemical feedstocks highlight the need for more sustainable solutions.
Businesses in the UK face a tax on plastic packaging made mostly from new, rather than recycled, plastic, plus fees to cover the cost of collecting and recycling the packaging they use; as e-commerce continues to drive demand for protective packaging, there is an immediate need for high-performance, biodegradable alternatives.
The partnership builds on MMC’s existing commercial manufacture of Mushroom® Packaging at its Beeston facility in Nottinghamshire. Its technical team already includes two MSc graduates and one MEng graduate from the University of Nottingham. The company supplies established commercial customers including Raymarine.
Mycelium is the network of fine filaments produced by fungi. As it grows through agricultural plant material, it binds the fibres into a moulded composite. The researchers will investigate how fungal biology, feedstock structure and processing conditions can be controlled to improve strength relative to weight and deliver more consistent material properties.
Almudena Ortiz-Urquiza, Assistant Professor in Horticulture in the School of Biosciences at the University of Nottingham, is leading the project, she said. “Polystyrene protects much of what we buy online, but it lingers in the environment for centuries. Fungi can grow packaging from farm waste that does the same job and returns to the soil. Our challenge is to make it light, tough and water-resistant enough to replace polystyrene in everyday use.”
Across the partnership, materials and engineering researchers will develop surface treatments without fluorine to improve moisture resistance, surface durability and resistance to biological deterioration under demanding storage conditions. Preserving biodegradability is a central design requirement for the new materials and treatments.
The research will also establish how a composite’s internal structure affects its ability to absorb impacts, withstand repeated loading and retain performance during humidity exposure. These findings will help define which materials are suitable for particular packaging applications.
Dr Shirin Alexander, Associate Professor and Head of the Department of Chemistry at Swansea University, said: "Swansea University is leading the work package focused on developing sustainable and robust coatings for mycelium-based packaging materials. Working alongside Professor Davide Deganello from Mechanical Engineering and Professor Tariq Butt from Biosciences, we are combining expertise in materials chemistry, engineering and biological systems to create environmentally compatible coatings that enhance durability and moisture resistance while maintaining the sustainability credentials of these innovative packaging materials."
MMC helped design the programme and will lead its industrial translation, with its technical team involved across all four work packages. Trials within the company’s manufacturing environment will assess consistency between batches, throughput, defects, energy use and cost. The results will guide further development and help identify practical routes to commercial use.
Paul Gilligan, Founder and CEO of Magical Mushroom Company®, said: “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.
“As we scale our business, our contribution centres on our team’s expertise and manufacturing facilities. We are excited about the opportunities to contribute further as the project evolves. For the first time since MMC was founded, we now have two real quality engineers working alongside our science team. The programme will support our scientists and engineers with academic expertise and testing, helping us strengthen product performance and manufacturing consistency.”