The need for functional and sustainable alternatives to plastic packaging materials is currently unavoidable. This trend is driven by both legislation, particularly the EU regulation on packaging and packaging waste, and corporate social responsibility goals. Fungal mycelium-based packaging offers a solution, but its widespread adoption has so far been hindered by limitations in production efficiency.
MYCO has perfected a manufacturing process that overcomes these barriers. Thanks to innovations, the company has transitioned from concept to industrial production.
Composition and principle of the composite
The material is based on a composite consisting of two main components:
- Mycelium (mycelia): Functions as a natural, spontaneously growing binder.
- Organic substrate: Consists of waste products from the agricultural and timber industries (e.g., sawdust, hemp shives) which contain lignin and cellulose and thus serve as filler and nutrient source for the mycelium.
During cultivation, the mycelium permeates the substrate, creating a strong and lightweight fibrous network that gives the material the necessary mechanical properties, including shock-absorbing capability.
Key phases and innovations in the manufacturing process
The efficiency and scalability of MYCO’s process are based on the optimization of two production phases.
These enable large-scale production of Myco material and the filling of paper capsules for the MYCO 4Pack packaging system, which received the Red Dot Design award for its functional design.
Substrate preparation and sterilization
The goal of this phase is to create an environment for mycelium growth. The original batch method, based on several hours of substrate steaming, was time- and energy-inefficient and significantly limited the continuity and overall capacity of the production process.
By introducing a continuous sterilization line, the sterilization time was reduced from hours to minutes. This led to a reduction in energy consumption, an increase in production capacity, and ensured a continuous flow of material to the next production phase. Sterilization is carried out by heat; no harmful chemicals are used in the production.
Substrate inoculation
Accurate mycelium dosing in the substrate is crucial for proper growth. Manual inoculation showed a high risk of contamination and uneven permeation.
MYCO has implemented automated mycelium inoculation technology, which allows for precise and uniform dosing directly into the substrate within the production line. This reduces the risk of contamination and shortens the overall maturation time by up to 50 %.
The product forming itself is often the longest phase in competing technologies, taking days. MYCO has developed its own fast forming process that takes seconds. This process enables large-scale production of Myco material and the filling of paper capsules for the MYCO 4Pack packaging system, which received the Red Dot Design award for its functional design.
Environmental aspects of production
The resulting production process is designed with an emphasis on minimizing environmental impact.
- Carbon footprint: CO₂ emissions in the “cradle-to-gate” cycle are even negative due to the binding of biogenic carbon in Myco material, amounting to approximately -1.35 kg of CO₂ per 1 kg of material. For comparison, the production of 1 kg of polystyrene means approximately 3.68 kg of CO₂.
- Raw material source: The use of local waste raw materials reduces dependence on primary sources.
- Energy intensity: Mycelium growth itself occurs at room temperature, which minimizes energy consumption.
- End of life: The material is biodegradable and compostable.
Commercial availability
By transitioning to continuous and automated processes, MYCO, led by David Šohaj Minařík, has achieved industrial efficiency, offering a commercially successful and scalable solution for demanding applications. This position is further confirmed by its successful entry into the German market, where the company is already fulfilling its first orders.