An EPS foam alternatives guide for purchasing teams

Alternatives, for the days ahead

EPS (Expanded Polystyrene) foam is cheap, light and easy to mold, which is why it has been used for so long. After unboxing, though, it often becomes waste nobody collects for recycling. This page compares the alternatives in real use, so purchasing and packaging teams can start from the same facts.

Comparing EPS foam alternatives

We compare raw materials, forming and end of life. We do not compare cushioning performance, because results depend on thickness, shape and product weight and must be tested with the real product.

EPS foam

Made from: Polystyrene, derived from petrochemicals
Forming: Molded
After use: Technically recyclable, but rarely collected separately
Typical use: Heavy goods, electronics

Velvet-lined foam

Made from: EVA or PE foam (petrochemical) covered with velvet fabric or flocked fibres, bonded with adhesive
Forming: Die-cut or CNC-cut cavities, then lined
After use: Foam, fabric and glue are bonded together, hard to separate for recycling, usually general waste
Typical use: Jewellery, watches, perfume, premium gift boxes

Folded corrugated board

Made from: Paper pulp
Forming: Folded into slots or frames
After use: Recyclable in paper streams
Typical use: Flat, regular products

Molded pulp

Made from: Paper or plant pulp
Forming: Molded
After use: Depends on formulation and coatings
Typical use: Bottles, small to medium items

Honeycomb paper

Made from: Paper
Forming: Cut into sheets, blocks or corners
After use: Recyclable in paper streams
Typical use: Bases, edges, corners

MyceliumOur material

Made from: Mycelium grown on agricultural residues
Forming: Grown in a mold
After use: The material itself is entirely biomass
Typical use: Gift sets and special collections

These are general characteristics of each material group and individual suppliers may differ. Always ask suppliers directly. Illustrations by Thereon; the mycelium photo shows our own work.

5 questions to answer before moving away from foam

How heavy is the product, and from what height might it fall? These two numbers drive insert thickness more than material choice.
How do you ship? Single parcels, pallets to retailers, or export carry very different risks.
Will it meet humidity in transit? Paper and biomass materials are more sensitive to moisture than plastics.
How many per month, and what budget per piece? Some options only pay off at high volume.
What do you want to tell customers? Every word printed on the box needs evidence behind it.

How to run a simple test yourself

Before switching, run a simple drop test with your real product and record the conditions.

Product weight, box size and insert thickness
Drop height, number of drops, and the face or corner that hits
Product condition after each test, with photos

For results you can reference, standards include ASTM D1596 for the shock-cushioning characteristics of materials and the ISTA series for transit simulation. Your own tests are useful for internal decisions but should not be used as customer-facing claims.

If your brand wants to talk about sustainability

Brands that talk about sustainability carry a high greenwashing risk, because one overstated word makes customers question the whole brand. Here are statements about our material, sorted by the evidence available.

Fine to use

This insert is grown from mycelium (the root network of fungi) on agricultural residues from Thailand
Not made from petrochemicals
Grown from nature.

Avoid

100% biodegradable, or disappears in soil
Cushions as well as foam
Certified, or meets the standard

Who mycelium suits

Brands that ship products as gift sets, in modest volumes, and want the insert to be part of the brand story, such as candles, reed diffusers and skincare.

Already have a cushioning spec to meet?

Send it. We will test against your conditions and share the results.

Send your spec, get a free sample

FAQ

Frequently asked questions

Can we print 100% biodegradable on the box?

We do not recommend it. Any biodegradability claim needs test results to a recognised standard behind it. Statements you can use: grown from mycelium on agricultural residues, and not made from petrochemicals.

How long does EPS foam take to break down?

There is no exact figure. The commonly cited estimate is several hundred years, because polystyrene, the material EPS is made of, is barely broken down by microorganisms in ordinary environments. It fragments into smaller pieces rather than disappearing.

Is EPS foam recyclable?

Technically yes, but foam is light and bulky, so collecting and transporting it for recycling is uneconomic in many places. Cushioning foam from parcels often ends up in general waste.

Which material cushions best?

There is no single answer. Results depend on product weight, insert thickness, shape and drop height. The reliable answer comes from testing with your product under conditions close to real shipping.

Does mycelium cushion as well as foam?

Results depend on thickness, shape and product weight, so we do not give blanket comparisons. If you have a spec to meet, send it. We will test against your conditions and share the results.

Journal