Boosting Client’s Sustainability By Replacing Styrofoam in Protective Transport Packaging

A leading global packaging and materials manufacturer approached GreyB to better understand how sustainability pressures and customer preferences could shape the future of Styrofoam in protective transport packaging.

Expanded Polystyrene (EPS), commonly known as Styrofoam, is lightweight and effective for cushioning, but presents challenges at the end of life. Although EPS is approximately 98% air and only ~2% plastic, most of it is not recycled at scale due to infrastructure limitations. In North America, for example, only around 30–31% of EPS packaging waste is collected and recycled. The remainder is typically discarded.

Against this backdrop, the client sought a structured evaluation of alternative material solutions and a clear view of how diversification beyond traditional EPS could be approached.

Challenges in Replacing EPS

One of the key insights from the analysis was that EPS replacement is not a simple one-to-one material swap. EPS serves a wide range of protective functions across electronics, pharmaceuticals, food and beverage, industrial goods, cosmetics, and e-commerce. No single alternative today fully matches EPS across all use cases in terms of performance, cost, and scale.

Instead, a portfolio-based approach was recommended. This involved mapping different solutions to specific application clusters, identifying solutions that could address a meaningful share of near-term use cases, and positioning emerging materials for gradual adoption as their operational maturity improves in the long term.

Research Process – How Did GreyB Help?

Identifying Emerging EPS Alternatives

The process began with a broad investigation into emerging protective packaging materials positioned as alternatives to EPS. This included reviewing commercially available products, pilot-stage innovations, and supplier landscapes across multiple material categories. The objective was to build a comprehensive understanding of the evolving ecosystem and identify solutions relevant to protective transport packaging applications. The detailed analysis revealed multiple promising solutions, including the following: 

Magical Mushroom Company 

This is a mycelium-based protective packaging manufacturer, whose solution is designed to deliver cushioning performance comparable to EPS in transport applications. The packaging is manufactured in custom molds through a collaborative design and rapid in-house prototyping process, enabling geometry-specific solutions with lead times of approximately 7 days.

InfinityCore®

InfinityCore® is a molded, fiber-based protective packaging solution from CMS Green, designed to replace plastic foam. The material focuses on improving recyclability and end-of-life performance while providing protective strength through engineered fiber structures comparable to Styrofoam across a range of applications.

Detailed Evaluation of Technologies

Identified materials and suppliers were screened to understand their suitability for protective packaging use cases. The focus was on solutions that could address cushioning and transport-protection requirements traditionally served by EPS. This step helped narrow the landscape to materials with potential for practical applications.

Filtering and Relevancy Assessment

A structured review ensured that only the most relevant and feasible solutions were considered for further evaluation. The team examined overall maturity, market presence, and general alignment with evolving sustainability expectations. This stage helped distinguish emerging concepts from commercially deployable options.

Shortlisting Solutions

The shortlisted solutions were grouped by their potential role in different protective packaging applications. This enabled the development of a diversified material perspective rather than a single-alternative approach. The outcome supported a clearer view of near-term opportunities and longer-term innovation pathways.

Want to benchmark solutions against cost, regulatory compliance, and operational feasibility?

Transitioning from a legacy material involves balancing performance, cost, regulatory compliance, and operational feasibility. GreyB works with similar materials and packaging manufacturers to evaluate emerging technologies, assess diversification pathways, and develop structured strategies aligned with evolving sustainability requirements.

If you are evaluating diversification pathways or exploring sustainable alternatives to legacy materials, connect with our experts to discuss how we can support your transition strategy.