Emma Wilson
Mushroom packaging is an eco-friendly alternative to polystyrene and plastics. It is made from mycelium—the root structure of mushrooms—and agricultural waste. The mycelium is grown into shape inside custom moulds, digesting agricultural by-products and binding into any shape needed. After a few days, the threads spread across the mould. Once they have formed the desired shape, the mycelium is heated to stop the growth process. The final product is fully compostable and biodegradable, breaking down within weeks or months after being buried beneath the soil.
| Characteristics | Values |
|---|---|
| Composition | Mycelium, mushroom roots, agricultural waste |
| Manufacturing Process | Grown into shape inside custom moulds |
| Growth Time | 4-7 days |
| Properties | Lightweight, mouldable, compostable, insulating |
| Benefits | Eco-friendly, versatile, economical, protective |
| Applications | Storing heavy items, luxury goods, food and beverages |
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What You'll Learn
Mycelium and its properties
Mycelium is the root-like structure of a fungus, consisting of a mass of branching, thread-like, elongated cells called hyphae. These cells are separated by internal porous cross walls, named septa, and are enclosed within a tubular cell wall. Mycelium grows due to its symbiotic relationship with the materials that feed it, forming entangled networks of branching fibres.
Mycelium has a unique self-assembly property that allows it to grow on a wide range of organic materials, including waste. It secretes corrosive enzymes that enable it to degrade and colonize organic substrates. During this process, mycelium develops a dense network of thin strands that fuse together within the organic substrate, creating a solid material that can bind multiple substrates together. This adhesive property is responsible for its diverse applications, as it can be used to bind various substances.
Mycelium has a relatively high strength-to-weight ratio and a much lower embodied energy compared to traditional building materials. It can be grown into custom moulds, making it advantageous for customization and architectural features. Mycelium also has desirable properties such as being lightweight, compostable, biodegradable, and thermally insulating.
However, mycelium has some disadvantages that hinder its large-scale implementation. It has low compressive strength compared to traditional building materials like concrete, and it requires specific environmental conditions, such as a constant source of air, a humid habitat, and protection from excessive water.
Mycelium-based composites (MBCs) are characterized as biodegradable materials derived from various fungal species and substrates. The properties of MBCs, such as tensile strength and density, are influenced by the type of fungal species and substrate used. The choice of nutrient substrates for the growth of hyphae can be tuned to control the structural and mechanical properties of the resulting mycelium material.
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Custom moulds
To begin, a detailed dimension drawing proposal is sent for approval before creating the custom moulds. The moulds are then filled with a MycoComposite™ mix, which is a combination of mycelium and agricultural waste such as hemp, corn husks, and wood chips. This mixture takes up to four days to grow into the desired form. The mycelium acts as a natural binding agent, creating a solid and durable structure.
Once the mycelium has grown into the desired shape, the pieces are removed from the moulds and left for another two days to develop their signature velvet-smooth texture. Kiln drying is then applied to remove water and prevent further growth, ensuring the packaging is dry, stable, and strong.
The custom moulding process allows for versatility in packaging design, enabling the creation of various shapes and sizes to meet specific product requirements. This adaptability, coupled with the eco-friendly and protective nature of mushroom packaging, makes it an attractive alternative to traditional packaging materials such as plastic and styrofoam.
Overall, the use of custom moulds in mushroom packaging production offers a sustainable and innovative approach to product protection, showcasing the potential of natural materials in the packaging industry.
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Kiln drying and heat treatment
After the mycelium has been grown into the desired shape, it undergoes kiln drying and heat treatment. This process removes water from the mycelium, rendering it inert and ensuring that the final packaging material stays dry, stable, and strong. The absence of water prevents the growth of mould or mildew, which could compromise the integrity of the packaging.
Kiln drying involves heating the mycelium at a high temperature for a prolonged period. The specific temperature and duration depend on the initial moisture content of the mycelium and the desired level of dryness for the final product. By slowly removing the moisture, kiln drying helps prevent the development of cracks or other defects in the mycelium structure.
The heat treatment process serves multiple purposes. Firstly, it stops the growth of the mycelium, ensuring that the packaging material maintains the desired shape and size. Secondly, heat treatment sterilizes the mycelium, eliminating any spores or allergens that may be present. This step is crucial for creating a safe and non-toxic packaging solution.
The temperature and duration of the heat treatment process are carefully controlled to achieve the desired level of sterilization without compromising the structural integrity of the mycelium. Excessive heat or prolonged exposure can cause the mycelium to degrade or become brittle, affecting the overall quality and performance of the packaging material.
Through kiln drying and heat treatment, the mycelium is transformed into a dry, inert, and sterile material that is safe and suitable for use as packaging. These processes are essential steps in the production of mushroom-based packaging, ensuring the stability, durability, and safety of the final product.
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Eco-friendliness and biodegradability
Mushroom packaging is an eco-friendly and biodegradable alternative to polystyrene and plastics. The material is made from mycelium—the root structure of mushrooms—and agricultural waste such as hemp, hurd, and corn husks. This process transforms waste into a useful and sustainable product that is fully biodegradable and compostable. Mushroom packaging can be safely disposed of at home by simply adding it to your garden or home compost, where it will naturally break down within weeks or months. This natural decomposition process mimics material cycling in nature, reducing landfill waste and pollution and ensuring a minimal environmental footprint.
The production of mushroom packaging is environmentally friendly as mushrooms require little space, water, and light to grow in large quantities. Additionally, the lightweight property of mushroom packaging means less fuel is consumed during shipping and delivery, further reducing environmental impact. The raw materials needed to cultivate the mycelium are also inexpensive and widely available, making mushroom packaging a cost-effective alternative to fossil fuel-derived materials.
One of the key benefits of mushroom packaging is its versatility. The mycelium can be grown into any shape and size, making it suitable for storing and protecting various types of goods, including heavy items such as computer servers and furniture. The material also offers excellent shock absorption and durability, ensuring that items remain safe and secure during transit.
Despite the many advantages of mushroom packaging, it is not as widely available as plastics. The challenge of increasing mushroom packaging production, especially in climates unsuitable for mushroom and mycelium cultivation, may deter companies from adopting this eco-friendly alternative. However, companies such as Ecovative have developed compostable packaging products made from mycelium, branded as MycoComposite™, which offer the same protective properties as polystyrene without contributing to plastic pollution.
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Cost and availability
Mushroom packaging is cost-competitive with petroleum-based foam polymers and requires a small fraction of the energy. The raw materials needed to cultivate the mycelium can be acquired at a low cost. However, mushroom packaging is still more expensive than styrofoam and low-grade moulded pulp, and it is not as widely available as plastics.
The cost of producing mushroom packaging depends on several factors, including the availability of agricultural waste, the growth rate of mushrooms, and the desired shape and size of the packaging. The production time for mushroom packaging is longer than that of styrofoam, and it requires specific conditions such as high temperatures and diverse microorganisms to grow effectively.
The price point for mushroom packaging is competitive with conventional foamed polymers, but it has not yet overtaken oil-derived materials like styrofoam in terms of cost and production speed. However, in certain markets such as the beauty industry, there is a demand for packaging that meets sustainability commitments, and mushroom packaging fills this niche.
The adoption of mushroom packaging by companies like Ikea and Dell has given scalability hopes to the industry. However, some critics argue that the success of mushroom packaging as a large-scale solution depends on consumers' commitment to properly disposing of the material. Additionally, industrial composting facilities often refuse compostable packaging, which can impact the "big picture" success of mushroom packaging as a widely adopted solution.
Overall, mushroom packaging offers a cost-effective and scalable alternative to traditional packaging materials, but it faces challenges in terms of production speed, availability, and consumer disposal habits.
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Frequently asked questions
Mushroom packaging is an eco-friendly alternative to polystyrene and plastics. It is made from mycelium, the root-like structure of mushrooms, and agricultural waste.
The process of making mushroom packaging starts with cleaning and sorting agricultural waste, which is then placed into custom moulds. Mycelium is then added and grows around the waste material into the desired shape. The final product is treated with heat to stop the growth process.
Mushroom packaging is a sustainable, biodegradable alternative to conventional materials. It is also lightweight, reducing fuel consumption during shipping and delivery. Additionally, it is cheap to produce and can be formed into any shape and size, making it a versatile packaging material.
Mushroom packaging is fully compostable and biodegradable, breaking down within weeks of being buried beneath the soil.
Mushroom packaging has been adopted by global companies such as Ikea and Dell, as well as companies carrying luxury goods like perfumes and champagnes.
