Zealafoam: biobased EPS packaging replacement with identical insulation properties

Overview

ZealaFoam is a New Zealand-developed biobased foam technology designed to replace expanded polystyrene (EPS/Styrofoam) packaging. It delivers comparable performance to polystyrene in the critical attributes of lightweight construction, thermal insulation, and impact resistance, while being made from plant-based materials that are industrially compostable. A key advantage is that ZealaFoam can be manufactured on existing polystyrene production equipment using existing moulds, allowing packaging producers to switch to a sustainable alternative without investing in new tooling. The material performs reliably at low temperatures down to -70 °C (-158 °F), though it has lower high-heat tolerance than conventional EPS.

Technical specifications

• Drop-in compatibility with existing polystyrene moulding equipment and moulds, enabling identical packaging shapes and sizes
• Plant-based composition that is industrially compostable, reducing reliance on fossil-fuel-derived plastics
• Insulation performance validated as comparable to EPS through in-house and independent testing
• Lightweight and impact-resistant structure suitable for protective and insulated packaging applications
• Low-temperature performance rated to -70 °C (-158 °F), suitable for cold-chain logistics and frozen goods
• Reduced high-heat tolerance compared to EPS, which may limit use in some high-temperature applications
• Two active research streams targeting home-compostable formulations and improved heat tolerance

Technology readiness level

ZealaFoam has been produced at meaningful scale in trials on multiple commercial polystyrene machines, demonstrating manufacturability and consistent material quality. Insulation and performance characteristics have been validated through both internal testing and independent third-party evaluation. Following a recently completed investment round, the technology is now scaling toward commercial production planned for 2024. The go-to-market strategy centres on licensing the technology to established polystyrene manufacturers worldwide, enabling rapid deployment using their existing production infrastructure.