Marketable mycelium-based materials derived from biogenic waste - FungiFacturing®

Substrate-based mycelium materials have the potential to serve as sustainable material alternatives for the construction, automotive and packaging industries.

However, fluctuating raw material qualities, unstable growth processes, material handling and long development cycles complicate the development and scaling of mycelium-based materials to an industrial scale. At the same time, there is often a lack of suitable infrastructure and reliable data needed to further develop materials in a targeted manner and optimize them for specific large-scale industrial applications.

We support companies in producing mycelium-based materials more reproducibly in a continuous process, validating them technically, and further developing them for specific applications. We guide you from the initial potential analysis of a waste material or material concept all the way to a functionalized prototype. The scalability of our processes is our top priority – our goal is to translate laboratory results into stable and  transferable processes. To achieve this, we investigate relevant process parameters under conditions close to those in a pilot plant and work with you to develop concepts for the continuous and scalable production of mycelium-based materials.

In our FungiFacturing® approach, we combine substrate and formulation development, process optimization, material characterization, functionalization and manufacturing technology. This provides you with a solid foundation for further developing mycelium materials, scaling up processes and preparing for industrial applications.

Are you already developing mycelium materials or mycelium-based products?

We’ll help you

• systematically evaluate raw materials and formulations
• make growth and manufacturing processes more reproducible
• shorten development cycles
• to verify material properties through metrological testing
• targeted optimization of formulations and process parameters
• functionalizing materials for specific applications
• scale up processes from the laboratory to larger scales.

Benefit from our expertise in materials science, our analytical capabilities and a fully equipped mycelium pilot plant.

Together, we’ll develop robust solutions for materials and processes. Leverage our practical experience to reduce your development costs and standardize your mycelium-based materials.

Do you have your own biogenic or other waste materials?

We assess whether your lignocellulosic waste materials – for example, from agriculture, the timber industry, the food industry or the paper industry – are technically suitable as substrates, additives or fillers for mycelium-based materials. To this end, we evaluate factors such as preparation, processability, mycelium growth and achievable material properties.

Based on this, we develop suitable formulations and explore potential applications as well as ecological and economic utilization prospects. This provides you with a sound basis for decision-making as you embark on a higher-value use of your waste materials. With our FungiFacturing® approach, we guide you from the initial potential assessment all the way to the prototype:  

Request a no-obligation consultation!

Potential analysis of feedstocks as mycelium-based materials or products

• evaluation of the technical suitability of residual materials
• screening of potential applications
• matching material potential with product requirements
• initial ecological and economic assessment
• recommendation of next development steps

Substrate and formulation development

• selection and preparation of suitable substrates
• development and optimization of formulations
• selection of suitable fungal species
• use of functional additives
• conducting feasibility studies

Process development and validation

• investigation of growth parameters
• analysis of causes of process and quality fluctuations
• optimization of growth times and process conditions
• evaluation of reproducibility and standardizability; scaling up of laboratory processes to larger production scales

Material characterization and analysis

Depending on the research question, we investigate, among other things:

• growth and microbiological properties
• thermal conductivity
• fire resistance
• biodegradability
• mechanical and application-specific material properties

You’ll receive reliable data that can be used to compare formulations, validate development decisions, and prioritize further optimization steps.

Functionalization

We develop mycelium-based materials specifically tailored to application-specific requirements, for example in the following areas:

• fire protection
• sound insulation and sound absorption
• thermal insulation
• surfaces and further processing

Functionalization can be achieved through the substrate formulation, during growth or by post-processing finished components.

Prototyping and molding technology

• substrate pastes suitable for 3D printing
• production of material samples and demonstrators
• development of application-specific molded parts
• investigation of different geometries and material structures

Feasibility studies and expert consulting

• technical feasibility studies
• environmental assessment (LCA)
• specialized workshops and training sessions for your development teams
• development of robust project outlines

Whether it’s substrate testing, formulation development, process stabilization, material development or a demonstrator: In a no-obligation initial consultation, we’ll assess your current situation and determine the best approach to address your specific needs.

We help you assess potential early on and make informed decisions about the next steps in your development. Schedule a no-obligation initial consultation with our experts.

If necessary, our discussion can take place under a confidentiality agreement.

During our discussion, we’ll determine which of our value propositions in the field of mushroom-based materials development can help your company move forward. The size of your business – is irrelevant: We provide the same professional research and development support to small businesses as we do to clients from the SME sector or DAX-listed companies.

Make targeted use of research funding

In many cases, our research and development services are eligible for funding – for example, through the research allowance. We can also work together to apply for larger, multi-year funding programs.

Our scaling capabilities for you

Today, mycelium-based materials are typically produced in individual batches using proven formulations, but with fluctuating lead times, uneven growth in larger components and a significant amount of manual labor. This is exactly where we come in: we work with you to develop a path from the batch process of mycelium-based material production to reproducible mass production.

Under realistic conditions, we examine the factors that determine robust production processes: raw material and substrate specifications with defined tolerance ranges, contamination control, homogeneous mycelial growth even in large-volume components and functional additives that improve fire resistance, acoustics or insulation performance without inhibiting growth.
We also examine the technical aspects of manufacturing, such as automatable dosing systems, efficient molding and handling, energy-efficient drying and inactivation and practical approaches to quality assurance. 

In this way, we support you on your journey toward a scalable plant and production concept for mycelium-based materials.

We would be happy to explain how we can support your specific scaling goals during a personal meeting!

Can you optimize an existing formulation?
Yes. We analyze substrate composition, fungal species, additives, and process conditions. The goal is to identify the causes of fluctuating growth or inconsistent material properties and to derive suitable optimization strategies.

How can fluctuating growth times be reduced?
To do this, we systematically examine relevant factors such as substrate quality, moisture content, preparation, formulation, and process conditions. Based on this analysis, we can identify critical parameters and develop test series for process optimization.

Can you produce prototypes?
Yes. Depending on the specific problem, we develop material samples, molded parts, demonstrators, and 3D-printed structures to practically investigate material properties and manufacturing approaches.

Can you test whether our waste material is suitable as a mycelium substrate?
Yes. Among other things, we evaluate the preparation and processability of the waste material, mycelium growth, and the achievable material properties. The results serve as the basis for deciding on further development steps.

Do you support the scaling of mycelium processes?
We investigate the transferability of laboratory processes to larger scales and identify critical process parameters. The goal is to create a robust foundation for further scaling and industrial implementation.

Can fungal materials be processed using 3D printing?
Yes. As part of research projects, lignocellulose-based pastes made from plant residues have been developed that can be 3D-printed and subsequently infiltrated by fungal mycelium. This allows for the creation of custom shapes and material structures.

What are mycelium-based materials?
Fungal materials are bio-based materials produced from fungal mycelium and plant residues. The mycelium – the fungal network – grows through a specially prepared substrate and binds the individual components into a stable material. After growth, the material is dried to prevent further fungal growth.

What applications are fungal materials suitable for?
Mycelium-based materials can be used in many areas, including:

• Packaging
• Sound absorbers
• thermal insulation
• facade elements
• furniture and interior products
• design and art objects
• construction products

The appropriate application depends on the desired material properties and the specific product requirements.

What role does the substrate play in mycelium-based materials?
The substrate forms the basis of the material. Its composition influences, among other things, growth, stability, processability, insulation performance, and acoustic properties. Therefore, the choice of substrate and formulation are specifically tailored to the respective application.

What raw materials are suitable for mycelium-based materials?
Numerous plant-based waste materials can be used for mycelium-based materials. These include, for example, straw, sawdust, wood chips, or spent grain from beer production. The use of such waste materials supports a resource-efficient and circular bioeconomy.

Mushrooms as material source

to the interview of 12.06.2020