Replace bubble wrap, foam, and thermocol with engineered mycelium-based systems, designed to fit into your existing packing process.
From bulk transport to individual product packaging: reduce variability, improve protection, and eliminate plastic.
void fill
manual layering
engineered cavity
precision fit
Across industries, fragile and precision products are still packed using bubble wrap layers, foam inserts, thermocol void fill, and manual overpacking.
These systems work, but they come with trade-offs.
Inconsistent Protection
Outcomes depend on who packed the box, not on an engineered standard.
High Packing Effort
Multi-step wrapping and void-fill add time on every single carton.
Excess Material Usage
Bulky plastic cushioning eats volume, weight, and warehouse space.
Poor Sustainability
Plastic-heavy packaging creates waste streams brands can no longer ignore.
We build mycelium-based secondary packaging that fits into existing packing workflows, replaces plastic-based cushioning, and delivers consistent, engineered protection across formats.
Solution 01 · Bulk Packaging
Replacing loose thermocol with mycelium pellets.
Used for
Key points
Solution 02 · Strip System
Replacing bubble wrap layers with strip-based inserts.
Designed for
Key benefits
Solution 03 · Molded Inserts
Replacing foam and molded thermocol inserts.
For
Key points
Anywhere fragile or precision products move through a supply chain, engineered cushioning beats manual wrapping.
Glass & Bottled Products
Perfumes, beverages, cosmetics, pharmaceuticals.
Precision Auto Components
Sensors, electronics, assemblies.
Electronics & Industrial Parts
Circuit boards, control units, modules.
Food & Grocery
Glass jars, gourmet products, specialty goods.
E-commerce & Mixed Shipments
Multi-SKU fragile packaging, marketplace fulfilment.
Lab & Scientific Instruments
Glassware, vials, calibration kits, precision equipment.
Replace improvised protection with a system you can spec, test, and scale.
Every format is engineered against the stresses cartons actually see, not idealized lab scenarios.
Shock Absorption
Distributed across multiple contact points, not a single wrap layer.
Reduced Movement & Vibration
Inserts hold products in place through transit, not just at rest.
Compression Stability
Holds shape under stacking loads encountered in real logistics flows.
Consistent Protection
Carton-to-carton performance doesn't depend on who packed it.
A new material only matters if it fits into how your line already runs.
Designed end-to-end to leave nothing behind that a supply chain shouldn't ship.
Bio-based Material
Grown from mycelium and agricultural biomass.
Compostable
Breaks down to soil in weeks, not centuries.
No Microplastics
Leaves no plastic residue in soil, water, or waste streams.
Lower Environmental Impact
Lighter footprint across material, energy, and end-of-life.
Three steps to validate mycelium-based cushioning inside your existing system, without disrupting how you pack today.
Step One
We identify a specific product, component, or shipment type based on your current packaging setup.
Outcome: A clearly defined use case aligned to your real packaging and logistics conditions.
Step Two
A mycelium-based configuration is designed to replace existing cushioning materials such as bubble wrap, foam, or thermocol.
Outcome: A validated packaging configuration ready for pilot use.
Step Three
Pilot units are produced and used in actual shipments under normal logistics conditions.
Outcome: Real-world validation of packaging performance in your logistics environment.
Practical benefits, not promises.
No change in packing workflow
Drops into the steps your team already runs.
Works with existing cartons
No new SKUs, no box re-engineering.
Tested in real shipment conditions
Validated under your actual transit routes.
Focus on performance and practicality
Engineered protection, not a promise tour.
Mycelium is the root network of fungi. Combined with agricultural biomass (hemp hurd, rice husk, sawdust) it grows into a dense composite that can be moulded into any cavity geometry, then heat-set into a rigid, lightweight, shock-absorbing insert.
It absorbs impact and distributes load the same way EPS thermocol does, with one structural difference: the cavity is shaped to your product, not generic foam squares stuffed into a carton.
On shock absorption and compression resistance, mycelium inserts match or exceed EPS thermocol, primarily because the geometry fits the product instead of relying on operator judgement to wrap, layer, and tape.
Where bubble wrap and loose-fill protection vary carton-to-carton based on who packed it, an engineered insert delivers the same protection on every carton. That predictability is usually the biggest performance gain.
Yes. After fungal growth, the insert is heat-treated to deactivate the mycelium and dry the structure. The finished insert is dimensionally stable across normal shipping temperature and humidity ranges, including monsoon transit on coastal Indian routes.
The insert is not a live biological material at the point of shipping, it does not regrow, attract pests, or change shape with humidity.
Yes, it is home-compostable. After unboxing, the insert can be broken up and added to soil or a compost bin, where it returns to organic matter within a few weeks.
No microplastics, no chemical binders, no special disposal stream. It can also be dissolved in water and used as a soil amendment for plants.
It drops into your current carton at the same step where you would otherwise add foam, wrap a bottle, or fill voids with peanuts. No new packing stations, no carton SKU changes, no operator retraining.
Most pilots take 5–10 minutes to introduce on a packing line. The insert is the only thing your team handles differently.
At production volume, mycelium inserts are typically priced in the same range as comparable moulded EPS or custom foam inserts, and meaningfully better than bubble wrap once you account for packing time, void-fill material, and rework on damaged shipments.
Per-unit pricing depends on insert geometry, mould complexity, and order volume. Specifics are shared after reviewing your SKU and shipping conditions.
Fragile and precision items: glass bottles (perfumes, spirits, cosmetics, pharma), instruments, electronics modules, machined components, and any SKU currently shipped with bubble wrap, EPS foam, thermocol, or hand-cut paper inserts.
Items above roughly 2 kg or with extreme aspect ratios (very long/thin, very heavy) need a separate design conversation. We will tell you upfront if the use case is not a fit.
No packaging system guarantees zero breakage, and we will not pretend otherwise.
The pilot is built to measure whether mycelium-based cushioning meaningfully reduces your current breakage rate under real shipping conditions, not a controlled lab scenario.
A pilot covers use-case definition, insert design, mould fabrication, and a small batch of inserts that you ship through your real logistics setup. Each pilot focuses on one SKU so the insert geometry can be optimised for that product.
To start, we need:
The pilot output is real-shipment performance data, not a theoretical lab result.
We focus on secondary packaging for fragile and precision products.
Across industries, products are still protected using bubble wrap, foam, and thermocol. While effective, these systems rely on manual layering and inconsistent cushioning.
We develop mycelium-based alternatives that replace these materials while fitting into existing packaging workflows. The focus is on real-world performance under actual transport conditions.
Founder & Product Lead, GlassTransit
GlassTransit was started by Saravana Kumar, whose interest in biomaterials began with hands-on experiments in mushroom cultivation. Over time, this curiosity developed into a broader effort to understand how mycelium and agricultural biomass can replace plastic cushioning used in shipping fragile and precision products. With a background in engineering leadership, Saravana brings a systems-oriented approach to sustainable materials, focusing not just on environmental impact, but also on practical performance in real transport conditions.
Secondary packaging cannot be solved generically. It must be evaluated in the context of your product, packaging, and logistics.
If you are currently using bubble wrap, foam, or thermocol and want to explore alternatives without changing your process: