A GREEN BIOCOMPOSITE OF WHEAT STRAW, MYCELIUM, AND PINE NEEDLE FOR CUSHIONING IN PACKAGING APPLICATIONS

Abstract

ABSTRACT The present invention discloses a method for creating a fully biodegradable biocomposite material reinforced with pine needles and wood powder, bound using the mycelium of Pleurotus ostreatus. The process involves inoculating P. ostreatus in a mixture of wheat straw, wood powder, and pine needles, allowing it to grow in a controlled environment at 25°C for 15 days to form a dense mycelial network. This network effectively binds the components into a robust three-dimensional structure. The biocomposite is then subjected to heat treatment to eliminate any residual living mycelia and drastically reduce moisture content, enhancing its shelf life. This innovative biocomposite presents a sustainable alternative to expanded polystyrene (EPS) with potential applications in internal packaging, cattle feed, fuel blocks, and organic fertilizers.

Specification

Description:TECHNICAL FIELD
[0001] The present invention relates to the development of mycelium-based composites reinforced with pine needles, specifically designed for internal packaging applications. This invention is positioned within the fields of sustainable development and biotechnology, offering an eco-friendly alternative to traditional packaging materials.
BACKGROUND
[0002] In the rapidly evolving landscape of sustainable materials and eco-friendly packaging solutions, industries are increasingly seeking alternatives to conventional, non-biodegradable materials. The demand for environmentally conscious products has grown significantly due to heightened awareness of the environmental impact caused by plastics and other synthetic materials. As a result, there is a pressing need to develop green materials that offer both functionality and sustainability for various applications, including internal packaging, where cushioning and protection of goods are critical.
[0003] An Indian Patent Application [202241049430] discloses the use of mycelium-based bricks and compares them to traditional clay bricks. It emphasizes the strength derived from mycelium content and the associated social and economic benefits of using such bricks as a sustainable construction material. This patent demonstrates the application of mycelium in construction but does not extend its utility to other industries, such as packaging.
[0004] Another Indian Patent Application [202241037137] presents a composition of lightweight bricks made from agricultural waste, polyester beads, and a binding agent. The focus is on the efficiency of this composition, which is highlighted as being energy-efficient, cost-effective, and sustainable. While this approach is innovative for construction, it does not address applications in other areas, such as eco-friendly packaging.
[0005] Despite these advancements in the mycelium and sustainable materials for construction, there is still an unmet need for environmentally friendly alternatives in the packaging industry. Further, the existing systems and methods for packaging solutions primarily focus on protection and cushioning but fail to incorporate sustainable or biodegradable components effectively. These systems do not adequately address the ecological concerns associated with the use of synthetic materials, nor do they explore the potential of natural, renewable resources for packaging applications. As industries strive to meet environmental regulations and consumer demand for eco-friendly products, the current options fall short of delivering a truly sustainable alternative.
[0006] Therefore, it is desirable to provide a system and method that integrates natural, biodegradable materials, such as mycelium and pine needles, to create a green biocomposite for internal packaging applications. Such an approach offers an environmentally friendly solution that addresses the limitations of conventional packaging methods while providing effective cushioning and protection for products.
SUMMARY
[0007] In an embodiment, a fully degradable biocomposite material is disclosed. In one example, the biocomposite material is composed of mycelium (Pleurotus ostreatus), pine needles, and wood powder, engineered to enhance mechanical properties through strategic reinforcement. Further, the present biocomposite is designed to offer superior strength and durability by utilizing the dense mycelial network of Pleurotus ostreatus, which binds the components into a cohesive structure.
[0008] The present invention demonstrates a proof of concept by inoculating P. ostreatus mycelium into a mixture comprising wheat straw (WS) as the substrate, wood powder (WD) as the filler material, and pine needles (PN) as the reinforcement. The growth process occurs at 25°C in complete darkness for a period of 15 days, resulting in the formation of a robust, three-dimensional mycelium network that effectively binds all three components. The ratio of these components can be varied to optimize mechanical properties such as tensile strength, elasticity, and compressive strength, tailored to specific applications.
[0009] After the growth phase, the composite undergoes a heat-killing process to terminate the living mycelia, ensuring no further biological activity. This process also significantly reduces moisture content, thereby enhancing the material's shelf life and making it suitable for long-term applications.
[0010] According to the present invention, the biocomposite has wide-ranging environmental and technological applications, including its use as an eco-friendly internal packaging material, an alternative cattle feed, fuel blocks for domestic energy use, and organic fertilizers for agricultural purposes.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, explain the disclosed principles.
[0012] FIG. 1 is a basic illustration of the process of formulation of mycelium-based biocomposite.
[0013] FIG. 2 illustrates the wheat straw (After size reduction by grinding operation).
[0014] FIG. 3 illustrates the wheat straw (After size reduction by grinding operation).
[0015] FIG. 4 is a flowchart representing the complete process of biocomposite fabrication by the growth of P. ostreatus on wheat straw media reinforced by pine needles with sawdust as filler material.
[0016] FIG. 5A illustrates the transverse plane view of a pine needle at 10X magnification under the microscope.
[0017] FIG. 5B illustrates the mycelium of P.ostreatus attached over the outer surface of pine needle at 40X magnification under a microscope.
[0018] FIG. 5C illustrates the mycelium of P.ostreatus sampled from the biocomposite surface before heat killing and dyed with lactophenol cotton blue dye, captured at 40X magnification under the microscope.
[0019] FIG. 6 illustrates the final product-(mycelium-based biocomposite) after drying and heat killing.
DETAILED DESCRIPTION
[0020] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[0021] References to "one embodiment," "at least one embodiment," "an embodiment," "one example," "an example," "for example," and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase "in an embodiment" does not necessarily refer to the same embodiment.
[0022] The present invention seeks to address the limitations of conventional systems by introducing a fully biodegradable mycelium-based biocomposite material reinforced with natural components like pine needles and wood powder. Further, the method enhances the mechanical properties of the biocomposite while providing an environmentally friendly alternative to synthetic materials. Moreover, the conventional approaches are inadequate as they fail to provide sustainable solutions and often exacerbate environmental problems through reliance on non-biodegradable materials, inefficient waste management, and high carbon footprints. As such, the present invention offers a sustainable, renewable, and ecologically responsible solution to these challenges.
[0023] In an embodiment, the present invention discloses a method for preparing a mycelium-based biocomposite material using a mixture of pine needles, wheat straw, and wood powder. The process involves specific proportions of these materials by dry mass, with pine needles constituting 10%, wheat straw 65%, and wood powder 25%. The mixture is supplemented with calcium sulfate (CaSO4) and calcium carbonate (CaCO3) to support the growth of Pleurotus ostreatus mycelium. The mycelium cultures, grown on Potato Dextrose Agar, are aseptically transferred to the substrate, and the mixture undergoes a controlled heat treatment at 90°C for 7 hours, including pressure release to ensure proper curing.
[0024] According to the present invention, the method specifies that the calcium sulfate is added in an amount of 20 grams, and calcium carbonate in an amount of 5 grams, per kilogram of the dry mixture. Before heat treatment, the biocomposite has a moisture content of 26.4975% by weight, and after the process, the dry density of the heat-killed and dried material reaches 0.128 grams/cm³, enhancing its mechanical properties and longevity.
[0025] Further, in the present invention the final biocomposite material itself, which incorporates the same specific proportions of components and has undergone heat treatment to ensure durability and stability. The biocomposite is positioned as a sustainable alternative, with its mechanical properties being improved through the unique combination of materials and the robust mycelial network created by P. ostreatus. The composition and structure of the material, along with its moisture content and dry density, make it suitable for various applications, offering a biodegradable and durable alternative to conventional materials.
[0026] According to the present invention, the substrate Preparation is disclosed. The preparation of substrates begins with a carefully controlled process. Wheat straw and pine needles are dried in a 311DS Labnet oven at 55°C for 24 hours to remove excess moisture. After drying, the materials are standardized by reducing them to an average size of 2.6 cm ±1.1 cm using a Bajaj GX3 mixer grinder. The average size is determined by randomly selecting and measuring 10 individual straw samples, followed by calculating the mean length. To create optimal conditions for mycelial growth, the wheat straw and pine needles are soaked in hot water at a temperature of 65-70°C for one hour, ensuring sufficient hydration and softening of the substrates.
[0027] According to the present invention, a Biocomposite Composition is disclosed. The formulation of the biocomposite incorporates a carefully balanced combination of materials. Wood powder is added as a filler to improve density and fill voids within the three-dimensional matrix, thereby enhancing the structural integrity of the composite. The mixture consists of 65% wheat straw, 10% pine needles, and 25% wood powder, all calculated on a dry weight basis.
[0028] According to the present invention, for every 1 kilogram of this mixture, 20 grams of calcium sulfate (CaSO4) and 5 grams of calcium carbonate (CaCO3) are added. These additives provide essential nutrients to support the optimal growth of the mycelium, promoting uniform colonization throughout the composite.
[0029] In an embodiment, autoclaving and sterilization are disclosed. Autoclaving and sterilization are essential steps in preparing the mixture for mycelial inoculation. The substrate mixture is first subjected to autoclaving to ensure the elimination of any microbial contaminants. After autoclaving, the mixture is allowed to cool for 2 hours at room temperature, with exposure to UV light inside a Laminar Air Flow (LAF) system to ensure complete sterilization. Following this, an aseptic transfer of 7-day-old Pleurotus ostreatus mycelium cultures, grown on Potato Dextrose Agar (PDA), is performed onto the sterilized substrate. The inoculated substrate is then sealed in sterilized bags and incubated at a constant temperature of 25°C in complete darkness for 7 days, promoting optimal mycelial growth throughout the biocomposite.
[0030] As according to the present invention, the molding and second incubation are disclosed. In the next phase, the biocomposite mixture is transferred into HELICO cube molds (dimensions: 70.6x70.6x70.6 mm, Cat. no. HC 42.10.1, IS 10080, Model No. L 1258650, Sr. no. 3288, wall thickness: 7 mm, base plate thickness: 4 mm), which have been thoroughly sterilized with ethanol. To prevent the biocomposite from adhering to the mold walls, a polyethylene lining is added during the filling process. Each mold is sealed in individual polymer bags to create an airtight environment, fostering further growth. The second incubation lasts for an additional 7 days at a constant temperature of 25°C in complete darkness, ensuring optimal conditions for continued mycelial development within the biocomposite.
[0031] According to the present invention, the Demolding and Heat Treatment process is disclosed. Following the 14-day incubation period, the biocomposites are ready for the demolding process. The molded blocks are carefully extracted and subjected to UV radiation for 5 minutes in a laminar airflow cabinet to ensure surface sterilization. The biocomposites are then placed in autoclavable polymer bags, which are sealed before undergoing a controlled heat treatment. This process is conducted in a convection oven set at 90°C for 5 to 7 hours. During the first 2 hours, the bags remain sealed to prevent moisture loss; after this period, the bags are opened to release water vapor pressure. The weight of the biocomposites is monitored at 20-minute intervals until a stable weight is achieved, confirming the removal of residual moisture and ensuring that the composite is dry and ready for further use.
[0032] Further, the present method discloses the formulation of the biocomposite is completed by processing through the above steps of sequencing. The precise processes of preparation, sterilization, inoculation, and controlled incubation and drying have been executed to ensure a stable, durable, and high-quality final product. This biocomposite is now ready for a variety of applications, demonstrating its suitability for use in sustainable packaging, alternative fuel, cattle feed, and organic fertilizers.
[0033] Referring now to Figure. 1 that illustrates the basic illustration of mycelium-based biocomposite formulation. This figure likely provides a high-level representation of the overall process flow, from the preparation of raw materials (pine needles, wheat straw, and wood powder) to the final formation of the biocomposite. Such as material mixing, inoculation with Pleurotus ostreatus mycelium, growth/incubation phases, and the final heat-killing process. This also emphasizes key control parameters such as the temperature (25°C for mycelium growth) and timing (15 days incubation), which are essential for optimizing the biocomposite's strength and functionality. As such, figure 1 gives a comprehensive view of the entire formulation pathway, ensuring a better understanding of each component's role in the final material.
[0034] Referring to FIG. 2, wheat straw is illustrated after being reduced in size through grinding, likely to around 2.6 cm ±1.1 cm. This reduction is essential as it creates a more uniform substrate, which facilitates more efficient colonization by the mycelium. From an advanced perspective, the size of the wheat straw plays a pivotal role in ensuring consistent bonding within the biocomposite matrix. A uniform particle size distribution optimizes the surface area available for mycelium to attach and grow, thus contributing to the overall mechanical integrity of the material. This highlights the mechanical preparation stage, which ensures that the raw straw is adequately prepared for integration into the biocomposite.
[0035] Fig. 3 illustrates the wheat straw after further size reduction. This figure provides another perspective on the wheat straw following further grinding operations. It could focus on the resulting particle distribution and possibly the cross-sectional view of the straw fibers. This stage includes the importance of consistent size reduction in controlling the final material properties such as porosity, mechanical strength, and bonding efficacy with mycelium. The refinement of raw materials at this stage sets the foundation for a homogeneous composite that can demonstrate enhanced performance characteristics such as tensile strength and compressive resilience.
[0036] FIG. 4 is a flowchart representing the complete process of biocomposite fabrication by the growth of P. ostreatus on wheat straw media reinforced by pine needles with sawdust as filler material. It likely details the steps of inoculating the wheat straw with P. ostreatus mycelium, reinforcement with pine needles, and filler integration with wood powder. The present flowchart includes sterilization, incubation, and heat-killing stages. Advanced input here would recognize the inclusion of crucial parameters such as controlled moisture content, the impact of heat treatment at 90°C on moisture reduction, and how the precise timing of bag sealing and pressure release affects the drying phase. Additionally, it highlights essential control points, such as maintaining complete darkness during incubation and the use of calcium sulfate (CaSO4) and calcium carbonate (CaCO3) to support growth, thereby ensuring consistency in the end product's properties.
[0037] FIG. 5A illustrates the the transverse plane view of a pine needle at 10X magnification under the microscope. In this microscopic view, the transverse cross-section of a pine needle is shown, offering insights into its structural integrity. The figure likely reveals the natural fiber orientation and void spaces, which are critical for understanding how the mycelium interacts with and reinforces the needle's structure. From an advanced material science perspective, this figure is key in illustrating the role of pine needles as reinforcement agents within the biocomposite. The fibers provide a scaffold for the mycelium to attach, which enhances the composite's mechanical properties. This structural visualization also explains how the natural morphology of pine needles contributes to the material's flexibility and compressive strength when subjected to external forces.
[0038] FIG. 5B illustrates the mycelium of P.ostreatus attached over the outer surface of a pine needle at 40X magnification under a microscope. The figure demonstrates how the mycelium binds to the pine needle, forming an integrated matrix. At this magnification, one can see the dense network of mycelium filaments that penetrate the pine needle's outer layers. Further, the present step provides a closer look at the bio-mechanical bonding that occurs, a critical factor in the strength and cohesion of the biocomposite. It highlights the biological synergy between the fungal mycelium and the natural reinforcement provided by the pine needle fibers, showcasing the biocomposite's ability to maintain structural integrity without relying on synthetic adhesives.
[0039] FIG. 5C illustrates the mycelium of P.ostreatus sampled from the biocomposite surface before heat killing and dyed with lactophenol cotton blue dye, captured at 40X magnification under the microscope. In this figure, mycelium is observed before the heat-killing process, stained with lactophenol cotton blue dye for clearer visualization. It shows the active fungal growth on the composite's surface, detailing the mycelium network that binds the components together. The significance of this figure lies in its demonstration of the robust colonization achieved by the mycelium before it is terminated via heat treatment. It also focuses on the uniformity of mycelial growth, which is crucial for ensuring the consistency of the final biocomposite product. The figure could be interpreted as highlighting the biocomposite's biological phase, wherein the mycelium's activity creates the structural foundation that gives the material its strength and biodegradability.
[0040] Fig. 6 illustrates the final product-(mycelium-based biocomposite) after drying and heat killing. This shows the finished product after undergoing the full heat-killing and drying process. It visually represents the biocomposite's uniform structure, with its moisture content significantly reduced and its biological activity halted. The heat treatment, conducted at 90°C for 7 hours, ensures the material is stable, durable, and ready for long-term use. This figure exemplifies the end goal of the entire process, presenting a sustainable, biodegradable alternative to conventional packaging materials such as expanded polystyrene (EPS). It could also indicate the physical characteristics of the biocomposite, such as surface texture, density (0.128 grams/cm³), and its readiness for various applications like cushioning in packaging.
[0041] Consider a practical scenario where a fragile electronic device, such as a smartphone, needs to be shipped to a customer using eco-friendly packaging. In this case, the present invention-a mycelium-based biocomposite composed of wheat straw, pine needles, and wood powder-serves as the internal cushioning material. The biocomposite is tailored to fit around the device, providing protective cushioning that absorbs shocks and vibrations during transit. Unlike traditional expanded polystyrene (EPS) packaging, this material is fully biodegradable, offering the same protective functionality while reducing environmental impact. After the device is delivered, the biocomposite can be disposed of in a composting facility, where it naturally decomposes, leaving no harmful waste behind. This not only ensures the safety of the product but also aligns with sustainable business practices, reducing carbon footprints and supporting circular economy goals.
[0042] The present invention offers several technical advantages over conventional synthetic packaging materials, such as expanded polystyrene (EPS) or plastic-based cushioning. One key advantage is its fully biodegradable composition, which includes wheat straw, pine needles, and wood powder, all bound together by a dense mycelial network. This enhanced material not only provides superior cushioning and impact absorption but also significantly reduces environmental impact by eliminating the use of non-renewable resources and harmful chemicals. Additionally, the use of Pleurotus ostreatus mycelium ensures strong mechanical properties, such as high tensile and compressive strength, while the incorporation of natural reinforcements like pine needles improves the structural integrity of the biocomposite. The heat-killing process further stabilizes the material, making it durable and suitable for long-term use in packaging. All these technical advancements collectively position the invention as a sustainable, eco-friendly alternative, offering both high functionality and compliance with modern environmental standards.
[0043] The present disclosure provides a concrete and tangible solution to a significant technical problem in the field of sustainable packaging, specifically addressing the need for eco-friendly alternatives to conventional, non-biodegradable materials like expanded polystyrene (EPS). The present disclosure offers specific technical features and functionalities, such as the use of a mycelium-based biocomposite reinforced with pine needles, wheat straw, and wood powder, which are all-natural and renewable resources. This biocomposite is designed to provide excellent cushioning and protective properties, while being fully biodegradable, thus solving the environmental impact caused by synthetic packaging. Additionally, the method disclosed involves strategic reinforcement of the composite through a controlled growth process of Pleurotus ostreatus mycelium, followed by heat treatment to terminate biological activity, ensuring both durability and long shelf life. These specific features make the biocomposite suitable not only for internal packaging applications but also for other uses such as alternative cattle feed, fuel blocks, and organic fertilizers, providing a multifunctional and environmentally responsible solution.
[0044] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
, Claims:Claims
WE CLAIM:
1. A method of preparing a mycelium-based biocomposite material, the method comprising:
mixing predetermined amounts of pine needles, wheat straw, and wood powder, based on their dry masses;
adding calcium sulfate (CaSO4) and calcium carbonate (CaCO3) to the mixture to support mycelial growth;
inoculating the sterilized substrate through the aseptic transfer of 7-day-old Pleurotus ostreatus mycelium cultures grown on Potato Dextrose Agar; and
performing a heat-killing and drying process by subjecting the mixture to controlled heat treatment at 90°C for 7 hours, wherein the process includes an initial sealing period of 2 hours, followed by intermittent opening of the bags to release pressure.

2. The method of claim 1, wherein the pine needles constitute 10%, wheat straw constitutes 65%, and wood powder constitutes 25% of the mixture by dry mass.

3. The method of claim 2, wherein calcium sulfate (CaSO4) is added in an amount of 20 grams, and calcium carbonate (CaCO3) is added in an amount of 5 grams per kilogram of the dry mixture.

4. The method of claim 1, wherein the moisture content of the freshly de-molded biocomposite, prior to the heat-killing process, is 26.4975% by weight.

5. The method of claim 1, wherein the dry density of the heat-killed and dried mycelium biocomposite is 0.128 grams/cm³.

6. A mycelium-based biocomposite material comprising:
pine needles constituting 10% of the mixture by dry mass;
wheat straw constituting 65% of the mixture by dry mass;
wood powder constituting 25% of the mixture by dry mass;
calcium sulfate (CaSO4) in an amount of 20 grams per kilogram of the dry mixture;
calcium carbonate (CaCO3) in an amount of 5 grams per kilogram of the dry mixture; and
Pleurotus ostreatus mycelium cultures grown on Potato Dextrose Agar, wherein the biocomposite has undergone a heat-killing and drying process involving controlled heat treatment at 90°C for 7 hours, including an initial sealing period of 2 hours followed by intermittent pressure release.

7. The mycelium-based biocomposite material of claim 6, wherein the moisture content of the freshly de-molded biocomposite, prior to the heat-killing process, is 26.4975% by weight.

8. The mycelium-based biocomposite material of claim 6, wherein the dry density of the heat-killed and dried mycelium biocomposite is 0.128 grams/cm³.

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