Progress 06/01/14 to 07/31/15
Outputs
Target Audience:Market analysis and performance metrics were evaluated alongside a current floral foam manufacturer and floral arrangement foam distributor. The target audience was the polymer research group leading evaluation and feedback of performance metrics. Upon determining a feasible product with amenable minimum viability metrics with prototype products, the Global VP of the collaborating company approved assistance in evaluation of market entry, enabling collaborative testing through their market test groups with field-testing feedback alongside their marketing group. The target audience shifted towards the US and global marketing team of collaborating manufacturer and distributor, to establish prototype products and test markets for pilot launch. The floral foam user (florists, non-supermarket based) market segment targeted includes small, environmentally conscious florists with a customer base willing to test sustainable material alternatives to traditional floral foam. Locally, a selection of local NY capital region florists (Flowers by Pesha, Troy, NY) provided testing and feedback, while broader reaching market groups included a national wholesale distributor with established channels in the Chicago corridor and Florida. Feedback was taken in regards to determine competative performance, pricing, and to isolate market entrypoints (cities and specific vendors) decided upon by real-time market evaluation of product performance. For development of scale-up procedures based on customer feedback and Phase I technical objectives, current business to business manufacturers and distributors are the target audience, to demonstrate technical readiness and strategy of a pilot program for distribution, map coordinated product launches for strategic market entry in collaboration with current distributor chain. Changes/Problems:Our collaborating manufacturer and distributor, as well as market testers, concluded that fine-particles of agricultural waste product held with Ecovative's fungal tissue (non-treated) exhibit desirable stem hold characteristics, and a viable path for dryfoam production. This product embodiment was near market ready while a wet-foam was deemed unreachable within the scope of the grant timeline with recent market testing feedback and updated requirements. By studying a range of potential substrates in Technical Objectives I and II we were able to identify several candidates that aligned well with current market metrics in dry floral foams. Technical Objective III provided the foundation to handle, process, quality assure, and scale production of a mycological floral foam. Biological testing under Technical Objecive II, borne out by parallel testing with our development partners and current market leader, confirmed a maple-coir blend as the most desirable particle scenario for wet floral foam applications. By collaborating with a current manufacturer on market feedback and evaluation of product, it was determined 1) wet foams were an inaccessible market at this time due to changing stringent demands in floral life support, and mechanical stability, and 2) that a dry floral arrangement and craft foam product embodiment was identified as a near market ready, and desirable for its sustainability and compostability properties. At this time a product pivot towards the desired dry floral foam was made, and strategic evaluation of tasks 1-8 provided information to minimize repeat work and develop a refined path towards testing and scaling the dry floral foam. Laboratory investigation into substrates and growth conditions for dry floral foams provided a candidate material for production. Performance metrics, filling procsess refinement, and quality control were determined at a prototyping stage-gate. Timeline, volume, locations, and marketing initiatives were set forth in collaboration with a current foam Manufacturer and distributor. A purchase order of 500 panels was placed, produced, and packaged for Stage I strategic market testing launch in November in Detroit, MI and Seattle, WA, Las Vegas, NV, and San Fransisco, CA in January 2016. These launches will take place with our market collaborator's current partnered conference centers for testing in large venue and exhibit build outs, with a goal to minimize plastic waste during sculpting and arrangement assembly and transitions. Stage II launch is anticipated to take place with roughly four times the initial order volume over the following 6 months, generating meaningful sales, and incorporating distribution centers on both the West and East coast. Stage III within the following 12 months is aimed to target remaining distribution centers in North America, incorporate new product embodiments and shapes, and begin evaluating European customers. European market composting legislature is too stringent for the majority of competing state of the art, providing a strategic advantage for Ecovative's materials, while improving GDP trhough exporting mycological composite foams grown using domestically source and up-cycled agricultural waste feedstock. What opportunities for training and professional development has the project provided?An Ecovative technician, Christina Kranz, was brought on-board to contribute to the support of this work plan. She graduated from the Ithica College with a Bachelors of Science in Environmental Science. Upon her hire and arrival at Ecovative, she had one-on-one mentoring with the Principal Investigator in order to help refine the floral foam treatement process, and establish the methodology and performance characterization as new techniques added to Ecovative's suite of methodologies. Christina has been integral with treatment method consistency, improvement, and scientific transition from lab to a product. How have the results been disseminated to communities of interest?Results and samples of the biocomposite have been shared with a lead manufacturer and distributor of floral foam media in monthly technical discussions to establish the interest and framework for development collaboration, manufacturing, distribution, and market entry. Dr. Tudryn, a supporting researcher, and a sales representative traveled to the collaborating floral foam manufacturer and distributor's headquarters in order to assist with an on-site market evaluation with test groups, alongside the floral foam manufacturer's Global VP and US marketing director. What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
Goals were subdivided into 8 tasks, as previously reported, including: Task 1: Substrate Development (Tech Objective 1) This task elucidated the substrate (agricultural waste) filler materials used to support fungal tissue colonization. Early screening results identified maple lignocellulosic waste as a primary substrate of focus for screen size variation. Alternate substrates in the work plan were eliminated based on inferior mechanical performance. Task 2: Inoculation methodology (Tech Objective 1) This task explored inoculation procedures to improve penetrability, increase homogeneity, and reduce cost through reduction in inoculation media. A more homogeneous method of fungal tissue dispersion reduced stress points in the composite acting as fracture nucleation sites during floral stem penetration. Improvements in overall colonization provide better mechanical stability for stem-hold, and an even distribution is critical to minimize resistant points during stem penetration Task 3: Reaction Optimization (Tech Objective 2) This task optimized post-treatment methods to increase absorbency and minimize compromised mechanical integrity. Optimizing the reaction parameters in this task provides predictable product performance when advancing to a scaled up process. Task 4: Mechanical Evaluation (Tech Objective 1) Single and multiple stem puncture tests using an apparatus adapted to an Instron testing frame were performed on handpacked samples and samples that were prepared using an air-conveyed automated filler. To improve testing throughput, use of a single-stem test was implemented using a 50 Newton compact force gauge with synthetic stem. Maximum resistance to penetration and stem retraction were measured and a standard operating procedure was developed to evaluate quality and performance quantitatively relative to customer metrics. Task 5: Composite Precursers using Production Methodology (Tech Objective 3) Two rounds of mycosorb products consisting of maple substrate have been produced using warehouse inoculation and incubation. Task 6: Optimize Post-growth Reactors (Technical Objective 3) Ecovative successfully designed and fabricated a prototype treatment setup to render composites water-absorbant. Task 7: Physical Handling Methods (Tech Objective 2, 3) Parameter variation and prototype preparation were tested using autofilling implemented on an air line and venturi air conveyer attached to Ecovative's protective packaging fillers. Task 8: Produce Parts for Market Feedback (Technical Objective 3) Dr. Tudryn and the Ecovative team lead successful production runs to produce consistent mycosorb floral foams for market and customer evaluation. A standard blend was chosen as a minimum viable product for use in market testing to solicit voice of customer and product impression. ADDED Task 9: Workplan Pivot Towards Dry Floral Foam [Tech Objective III] Following positive feedback of a dry floral foam arrangement product, and determination of both parties to pivot towards a readily commercialized product, Dr. Tudryn and his team led a three-tiered stage-gate process to initialize a product refinement and commercial launch. These three tiers represent a condensed version of the initial workplan, which included: 1) Lab-scale blend validation 2) Prototype demonstration and Quality metrics 3) Production runs for initial product launch The eight tasks in this work plan were targeted to tune and achieve physical, absorbent, and biological (floral life, antimicrobial) performance benchmarks in Ecovative's modified material, as set by a collaborating industrial manufacturer and distributor. Initially, substrate (agricultural waste, filler) type and size was screened for desirable water uptake and mechanical performance as composite material. Success was found using sawdust waste, however, mechanical performance required added fibers to enforce product rigidity during wetting and stem penetration. The chemical treatment was evaluated for parameters such as salt type, surfactant type and content, pH, temperature, and treatment duration. Results included identification of temperature as the governing factor in treatment efficacy governing absorbent characteristics. Feedback from industry leaders suggests that an improvement in floral life longevity is imperative for market adoption. Process design and production handling were key foci in identifying feasibility of product throughput. Initial designs and equipment were fabricated and tested. The designs have since been altered to adjust for treatment temperature findings. Market evaluation was performed on a local scale with success in determining customer interest and areas for improvement. This feedback was confirmed using a test market panel coordinated on-site at headquarters of industry leader and collaborator where critical feedback was obtained about product interest, impression, and areas for further development. Continued collaboration and an established development agreement with leading manufacturer further identified target market segment and reach technical specification performance with products under development in this work plan. After defining and reaching minimum viable product metrics defined by industry leader, a market group test was conducted and an initial product sale was made to a target market customer, providing level of market interest and information to better establish an acceptable market entry price point. The fulfilled order of an early prototype product was used to determine the customer's desired cost entry point and in-the-field product performance feedback. While performance metrics determined initially by collaborating manufacturer were largely obtained, the end-users feedback offered insight into two work plan changes: 1) wet floral foams would needed biological and mechanical improvement not anticipated or achievable within the remaining scope of the original work plan, and 2) a dry floral foam product format for silk and reusable arrangements is desirable and achievable today with minimal refinement of Ecovative's current technology and processing. Market feedback was digested and agreed upon by our collaborator and Ecovative's business development team, and a strategic market entry pivot was determined in order to shorten runway to market launch, minimize processing and capital equipment costs, and optimize positive brand alignment in a market with no competing green or disruptive technology. Laboratory investigation into substrates and growth conditions for dry floral foams provided a candidate material for production. Performance metrics, filling procsess refinement, and quality control were determined at a prototyping stage-gate. Timeline, volume, locations, and marketing initiatives were set forth in collaboration with our manufacturing distribution lead. A purchase order of 500 panels was placed, produced, and packaged for Stage I strategic market testing launch in November in Detroit, MI and also in Seattle, WA, Las Vegas, NV, and San Fransisco, CA in January 2016. These launches will take place with our collaborating foam producer's current partnered conference centers for testing in large venue and exhibit build outs, with a goal to minimize plastic waste during sculpting and arrangement assembly and transitions. Stage II launch is anticipated to take place with repeated order volumes of the initial launch over the following 6 months, generating meaningful sales, and incorporating distribution centers on both the West and East coast. Stage III within the following 12 months is aimed to target remaining distribution centers in North America, incorporate new product embodiments and shapes, and begin seeding European markets where composting legislature is too stringent for the majority of competing state of the art, and fitting for Ecovative's material's performance.
Publications
- Type:
Other
Status:
Other
Year Published:
2015
Citation:
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Progress 06/01/14 to 05/31/15
Outputs
Target Audience:Market analysis and performance metrics were evaluated alongside a current floral foam manufacturer and floral arrangement distributor. The target audience was the polymer research group and biologists leading analysis and feedback of performance metrics. Upon obtaining minimum viability metrics with prototype products, the Global VP of the collaborating company approved assistance in evaluation of market entry, enabling collaborative testing through their market test groups with field-testing feedback alongside their marketing group. The floral foam user (florists, non-supermarket based) market segment targeted includes small, environmentally conscious florists with a customer base willing to test sustainable material alternatives to traditional floral foam. Locally, a selection of local NY capital region florists (Flowers by Pesha, Troy, NY; Flowerworld, Troy, NY; Emil Nagengast) provided testing and feedback, while broader reaching market groups, including Cathy Cowgill (Cathy Cowgill Flowers: Canton, OH). Feedback was taken in regards to determine competative performance, pricing, and isolate market entrypoints decided upon by real-time market evaluation of product performance. For development of scale-up procedures based on customer feedback and Phase I technical objectives, SBIR Phase II directors are a target audience, to demonstrate technical readiness and strategy of a pilot program for distribution and market entry in collaboration with current distributors. Changes/Problems:Initial composites were found mechanically weak and susceptible to fracture during stem insertion. Adapting the work plan to incorporate fibers has improved mechanical integrity, and is a new focus of the substrate evaluation task. Current floral life is limited to 5 days or fewer with top-performing blends, recent customer feedback is now requesting 7 days. Work to reduce surfactant content using updated treatment methods, and screen new substrates that allow better water uptake in the floral stems, is underway. Floral life testing of these composites showed higher floral toxicity relative to water current foam controls. Concern of residual sodium salt causing floral toxicity between Day 3 and 5 lead to testing of potassium hydroxide in place of sodium hydroxide. Total dissolved salts were measured from the leachate water during floral life testing using a Mettler Toledo conductivity probe. This revealed a general increase in salt level from c.a. 500 ppm to 1000 ppm. Evaluation of US and global market segments are ongoing with collaborator marketing team and with Ecovative's business development team. Improvements in fracture resistance and floral life longevity, currently between 3-4 days, were required to improve to 7 days based on customer feedback. This has led to revisiting substrate types and fiber addition, with screening of non-myceliated substrate materials, reflected in adjustments to Task 1. Collaborating market evaluation determined that Ecovative's floral foams are exceptional when used for dry-arrangements. The collaborating manufacturer and distributor, as well as market testers, concluded that fine-particles of agricultural waste product held with Ecovative's fungal tissue (non-treated) exhibit desirable stem hold characteristics, and a viable path for dry-foam production is being mapped. Product refinement for performance such as currently in development: penetration, density, fracture resistance, and stem-hold are underway and offers a faster track to market than a water-soaked fungal composite product. Substrate screening and autofilling testing on non-treated floral fine particle composite foams is an anticipated goal that will produce an agricultural waste product for the floral foam market. This change shifts the commercialization plan sooner, focuses the target market and insertion points, and reduces the initial capital investment needed due to elimination of a complex treatment step. What opportunities for training and professional development has the project provided?An Ecovative technician, Christina Kranz, was brought on-board to contribute to the support of this work plan. She graduated from the Ithica College with a Bachelors of Science in Environmental Science. Upon her hire and arrival at Ecovative, she had one-on-one mentoring with the Principal Investigator in order to help refine the floral foam treatement process, and establish the methodology and performance characterization as new techniques added to Ecovative's suite of methodologies. Christina has been integral with treatment method consistency, improvement, and scientific transition from lab to a product. How have the results been disseminated to communities of interest?Results and samples of the biocomposite have been shared with a lead manufacturer and distributor of floral foam media in monthly technical discussions to establish the interest and framework for development collaboration, manufacturing, distribution, and market entry. Dr. Tudryn, a supporting researcher, and a sales representative traveled to the collaborating floral foam manufacturer and distributor's headquarters in order to assist with an on-site market evaluation with test groups, alongside the floral foam manufacturer's Global VP and US marketing director. What do you plan to do during the next reporting period to accomplish the goals?Modifications to the Autofiller pressure and motion will be tested. Standard maple and fiber blends will be used to test treatment workstation modifications to minimize product damage, and adjust treatment parameters in order to increase uptake performance. Treatements will be iterated in order to minimize phytotoxicity and increase antimicrobial activity.
Impacts
What was accomplished under these goals?
Task 1: Substrate Development (Tech Objective 1) This task elucidated the substrate (agricultural waste) filler materials used to support fungal tissue colonization. Early screening results identified maple lignocellulosic waste as a primary substrate of focus for screen size variation. Alternate substrates in the work plan were eliminated based on inferior mechanical performance. Corn stover resulted in an abundance of resilient fungal tissue not desirable for easy floral stem insertion. Further investigation into maple screen size was performed on various mesh sizes. Maple particles screened to fine mesh sizes offered superior stem insertion as measured by a synthetic stem fixture and load cell. Retraction force measured using the stem fixture provided values indicative of stem-hold performance. Customer benchmarks were significantly higher than mycelium composites, mirroring the results observed in floral testing where fracture occurred. These results, in concert with feedback from market testers and industry collaborator, prompted adjustment of the work plan to investigate fiber blends. Task 2: Inoculation methodology (Tech Objective 1) This task explored inoculation procedures to improve penetrability, increase homogeneity, and reduce cost through reduction in inoculation media. A more homogeneous method of fungal tissue dispersion reduced stress points in the composite acting as fracture nucleation sites during floral stem penetration. Improvements in overall colonization provide better mechanical stability for stem-hold, and an even distribution is critical to minimize resistant points during stem penetration Task 3: Reaction Optimization (Tech Objective 2) This task optimized post-treatment methods to increase absorbency and minimize compromised mechanical integrity. Optimizing the reaction parameters in this task provides predictable product performance when advancing to a scaled up process. To identify the level of cell chitin conversion during the post-treatment process, a series of reaction times and concentrations were executed prior to uptake testing and analysis. Recent experimentation highlighted a process change, where a mild surfactant decreased uptake time, and was optimized to for minimum required level. The selected surfactant was a naturally derived biodegradable product, effective at low concentrations and exhibits low phytotoxicity. Task 4: Mechanical Evaluation (Tech Objective 1) Single and multiple stem puncture tests using an apparatus adapted to an Instron testing frame were performed on hand-packed samples and samples that were prepared using an air-conveyed automated filler. To improve testing throughput, use of a single-stem test was implemented using a 50 Newton compact force gauge with synthetic stem. Maximum resistance to penetration and stem retraction were measured and a standard operating procedure was developed to evaluate quality and performance quantitatively relative to customer metrics. Task 5: Composite Precursers using Production Methodology (Tech Objective 3) Two rounds of mycosorb products consisting of maple substrate have been produced using warehouse inoculation and incubation. Two sets of 8 incubation bags successfully grew, and were used in large-scale grinding and processing equipment to evaluate process throughput and labor cost. Time and personnel have been used in refining a cost model for overhead evaluation and proper scale-up equipment in a commercialization plan. Roughly 12 units are yielded per bag, and half of each (8-bag) batch was used to determine compatibility with an automated air-conveyed assembly-line like process. Task 6: Optimize Post-growth Reactors (Technical Objective 3) Ecovative successfully designed and fabricated a prototype treatment setup to render composites water-absorbant. The stainless steel treatment workstation centered on a 30 gallon boiler tank modified with a 480V heating element. This high power heat source improved the cycle time of processing by heating water rapidly to treat a sufficient sample size of product each round. Heating is ongoing in the boiler, while a set of basins allows units to enter/exit treatment or rinse while the next volume of water is in preparation. Further optimization is needed to minimize part damage during conveyance and treatment (inluding: baffles, recirculation, and a modified tray/rack system) Task 7: Physical Handling Methods (Tech Objective 2, 3) Parameter variation and prototype preparation were tested using autofilling implemented on an air line and venturi air conveyer attached to Ecovative's protective packaging fillers. Clogging occurred in tube bends due to fine particle clumping. Future work requires a modified conveyor without sharp tubing angles. Fine particle overspray was encountered and minimized using a mesh screen on the fill head. Dynamic motions were compared to static filling applied to the fill cavity. Conclusions include hand-filling was quicker and produced less waste than the autofiller due to equipment design based on larger particles. Ongoing work uses hand-filling to asses cost modeling, updates and modifications to the autofiller technology are being drafted. A treatment rack system was built to contain 12 blocks at a time and convey wet/delicate parts using trays to and from the stainless steel treatment station with minimal handling. The rack/blocks are lifted using a winch and trolley setup to allow the operator to lift and relocate many blocks in one set (up to 400lbs), with minimal contact with hot components. Task 8: Produce Parts for Market Feedback (Technical Objective 3) Dr. Tudryn and the Ecovative team lead successful production runs to produce consistent mycosorb floral foams for market and customer evaluation. A standard blend was chosen as a minimum viable product for use in market testing to solicit voice of customer and product impression. Customer evaluation was performed both locally, and in concert with a global manufacturer and distributor of floral foam products. The minimum viable product was evaluated for aesthetics, wetting, cutting, and arrangement creation. These were demonstrated and were satisfactory at the customer's first impression, however not superior to current petroleum derived products with respect to fracture resistance. Ecovative engaged in technical collaboration from a majority market owner and traveled to their headquarters for market analysis. A series of Mycosorb floral blocks were produced, tested and were evaluated by Project managers, Market analysts, and florist market groups brought on-site for unbiased feedback. An international florist, and a business owner from Cathy Cowgill Flowers, Inc. in Canton, OH evaluated product impression and offered market feedback. The product aesthetics were desirable over current state of the art, to summarize: "if [current] foam were the same color, [I] would still prefer the eco-block. [Current] foam is too synthetic and doesn't offer the same natural, earthy look and feel." The color and texture fulfill a niche market where a non-green, southwestern appeal is preferred, and not fulfilled with standard [current] foam. Freedom roses were used for stem penetration testing, and suggestions were made for improvement in fracture. A 96 unit purchase order was fulfilled to Cathy Cowgill Flowers for additional testing. This provided Ecovative (1) product form factor/shape, and (2) target pricing. The product is desirable in with 4" sides to fit current containers, an important variation from the product cut upon arrival. A product price was negotiated for the two cases provided, determining a 15% premium is acceptable if product performance metrics were met. Ecovative designed and thermoformed tooling cavities for cube parts and fulfilled the order using maple blend samples grown and treated using lab and production methods.
Publications
- Type:
Other
Status:
Other
Year Published:
2015
Citation:
-
|