A system and process of printing a package of expanded material (e.g., expanded starch, foam or other expanded material). The expanded material can be heated and extruded, poured, sprayed, or otherwise applied in malleable form that sets up to become a porous protective covering for an item to be packaged. In an example, a layer of expanded material is laid down, and the item in a protective covering (e.g., a plastic bag, sleeve, coating, etc.) is positioned on the layer of expanded material. Additional layers or expanded material may be applied, thereby encasing the item. The top surface of the expanded material may be flattened, such as by operation of a roller, press, or cutter. The top surface may be sprayed with a shellac sealant, paint, or other coating, to allow printing of a label on the top surface.