MycoComposite

Topiary candle packaged in Mushroom Packaging / Source: Topiary

BeautyCompostableEuropeFood & BeverageLightweightMyceliumMycoCompositeNorth AmericaOceaniaPackagingWater Repellent

WHAT WE SAY:

Nature is abundant with circular systems. Everything that nature creates, goes back to the earth as food. Meanwhile, much of what man creates traps finite resources in indestructible forms for centuries, eventually poisoning the land from which it came.

Ecovative’s MycoComposite mycelium material emulates nature’s existing circularity, borrowing from the earth and returning to it in its natural state, decomposing into key elements that go on to create new life. It all sounds perfect in theory. Our only caveat for Ecovative is for transparency on all finished product, to ensure zero petrochemicals or plastics have been added in the final stages by others.

MycoComposite

WHAT IS MYCOCOMPOSITE?

MycoComposite is made from a combination of agricultural waste and Mycelium, ‘grown’ over a period of seven days into a durable, plastic-free, foam-like material that’s suitable for use as packaging, in construction and as an architectural material.
MycoComposite’s most well known application is Mushroom Packaging, a licensee of Ecovative’s technology with the aim of replacing polystyrene foams, such as Styrofoam in packaging.
Cradle to Cradle Gold Certified, Mushroom Packaging can be grown into any shape and has a shelf-life of 30 years when kept in dry conditions. At the end of its useful life it biodegrades into key nutrients, enhancing plant growth when added to soil. The products are home compostable in 45 days and marine compostable.
Between launch and 2020, Ecovative grew over five million pounds of Mushroom Packaging and supplies key brands, such as Ffern, Seedlip, Loli and Sanctuary fragrance. A high profile collaboration with IKEA in 2020 has the potential to see the global home retailer replace its styrofoam with Mushroom Packaging.
The use of MycoComposite is cost competitive with traditional expanded foam polymers. It is currently available directly from Ecovative licensed partners and distributors: West Cost, Grow.bio and Mushroom Packaging in the US; Magical Mushroom Co. and Grown.bio in the UK and EU; and BioFab in Oceania.

KEY PROPERTIES:

Compostable
Lightweight
Water Repellent

INDUSTRY:

Beauty
Food & Beverage
Packaging

AVAILABILITY:

Commercially Available

DIVE DEEPER:

Over 900,000 metric tons of household, plastic foam packaging is used annually. While it is technically possible to recycle it, it is not financially feasible and therefore the end-of-life is today is mostly landfill or toxic incineration.
Due to the high energy and fossil fuel content of this plastic foam, each metric ton is equivalent to 1.78 metric tons of petroleum.
MycoComposite combats this linear use of plastic-based foams thanks to mycelium, the interconnected network of branched hyphae. When grown through a given substrate, it can be formed into solid shapes, creating a strong web of organic structural matter that has many applications in the real world. If MycoComposite replaced all use of plastic foam for packaging, it would save 1.45 million metric tons annually.
The bio-fabrication of MycoComposite requires mycelium and a feedstock to provide the base framework for growth. The feedstock for MycoComposite varies dependent on location, allowing Ecovative to harness locally available resources. Typical base materials include Hemp (hurd), corn and timber, and as the process requires only the byproducts of the agricultural industry it does not compete with other sectors.
Depending on its final use, Ecovative chooses the appropriate strain of mycelium from its Mycelium Foundry to ensure the properties of the resulting MycoComposite are suitable.
Moulds are used to control the shape of the MycoComposite. The feedstock and mycelium matter are pressed into the mould, then held in a climate controlled environment while the required shape grows.
The mycelium is fast growing, meaning solutions can be grown in moulds in seven days. No post-processing is required and pieces are desiccated (dried out through heat treatment) to make sure the mycelium stops growing and is shipped without living fungus.
The resultant MycoComposite material is solid, flame resistant, naturally hydrophobic (but unsuitable for submerging), tactile and features a natural organic variation in appearance.
It is also low energy to produce. A comparative LCA shows that MycoComposite uses one-tenth of the energy and emits one-eighth of the GHGs as an equivalent volume of plastic foam.
As well as packaging, MycoComposite makes an effective insulation material thanks to its natural flame resistance and thermal and acoustic insulating properties. As a result, the coming years will see MycoComposite become a viable replacement for foams, timber and plastics in construction, and used as insulation, door cores, flooring, panelling and cabinetry.
Recognised certifications held by MycoComposite include ASTM D5400 from the Biodegradable Product Institute, ASTM D6866 for USDA Biobased Preferred and Red-List Free from International Living Future Institute.

Loli Beauty using protective Mushroom Packaging / Source: Ecovative

Mycelium Mushroom Packaging / Source: Ecovative

KEY FACTS:

30 years

Mushroom Packaging has a shelf-life of 30 years, when kept in dry conditions.

45 days

The products are home compostable in 45 days and marine compostable.

1.45 million MT

If MycoComposite replaced all use of plastic foam for packaging, it would save 1.45 million metric tons annually.

Key Questions to Ask:

Are you able to invest in the moulds?

MycoComposite has to be grown in a mould and every batch you order must have an equivalent number of moulds made to facilitate it, requiring significant investment the larger your orders become. Work with the supplier to establish what the moulds are made of (it is often plastic), how long they last and how many will be needed. If the plan is to reuse the moulds to fulfill one order, then finished products cannot all be produced simultaneously, extending run time.

Can you minimise the amount of shipping required?

Due to their solid nature, MycoComposite products cannot be nested like cartonboard or vacuum formed products. This means a significantly larger amount of shipping space is required. Ensure you source from a licensee as close to the fulfilling centre as possible to help reduce emissions from transit.

What quantity of MycoComposite do you require?

While it only takes seven days to grow MycoCompostite, the process is slower than traditional manufacturing methods. This makes it more suitable for small-to-medium batch brands and products. It also creates an opportunity to educate the end consumer about the process. A made-to-order business model allows you the time to grow the mycelium after purchase, while sharing the growing process with the consumer, adding further value to the end product.

Are you ready to embrace a perfectly imperfect aesthetic?

No two pieces of MycoComposite will be exactly the same. The organic process of growing the material means each one is unique and it is difficult to create really crisp finishes. This is the new language of design - a celebration of its idiosyncrasies - but consider if your client is prepared to go off the beaten track.

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