Mushroom farming
Welcome to our website, your source for comprehensive information on mushroom production basics. Our focus primarily lies on the commercial production of white button mushrooms, also known as Agaricus bisporus. This content is particularly crafted for those looking to start a business in mushroom production.
Mushrooms growing in indoor, climate-controlled environments, housed in long, insulated rooms that range from 20 to 45 meters in length and at least 6.5 meters wide. These rooms, sealed off from the outside world, protect the crops from pests such as the mushroom fly, Megaselia halterata, and other infections. Inside these rooms, mushrooms are grown on shelves stacked 5 to 8 layers high. It’s common to find two rows of shelves, although some setups accommodate three or four. These shelves are filled with a substrate that provides food and water for the mushrooms. Nowadays, this substrate, already fully grown with mushroom mycelium, is delivered ready for use. Machines are used to fill the shelves with substrate, and mushrooms appear in flushes. A typical room cycle lasts between 4 to 7 weeks, yielding 2 or 3 flushes. In terms of products, we primarily focus on fresh mushrooms. These mushrooms are harvested, cooled, and packaged. There are also machine-trimmed mushrooms, which are too damaged for immediate sale but are suitable for food processing. This includes canned mushrooms, pizza toppings, soups, sliced and frozen mushrooms, dried mushrooms, and more.
Mushroom production has a unique combination of properties that make it so interesting to invest in.
- High Selling Price: Fresh mushrooms, due to their limited shelf life, often command high prices and are safe from product dumping from outside regions.
- Easy Raw Material Transport: The substrate used for mushroom growth can be easily transported and stored for an extended period, making it feasible to produce mushrooms on high-quality substrate almost anywhere.
- High Production Capacity: Indoor mushroom farming operates on a multi-layer system, generating a significant output in a comparatively small space all year round
- Health and Environmental Image: With the increasing global trend towards healthier and environmentally-friendly products, mushroom consumption is on the rise.
Challenges
Despite these advantages, starting a mushroom farm requires careful consideration of certain challenges.
- Labor is intensive; workers need rigorous training, particularly for fresh mushroom
picking. - Diseases must be controlled through meticulous farm design, operation, and discipline.
- Knowledge of growing, a good mushroom grower requires both theoretical understanding and practical experience.
There are 3 systems that are common in the modern mushroom industry.
- Containers: Ideal for small-scale production, the container system requires a sea container equipped with non-standard shelves and a climate system. This system has higher operational costs for white button mushrooms but may be viable for other mushroom species or unique situations.
- Sheds: Also known as mushroom tunnels or span tunnels, this system is built on a concrete floor and uses a steel tube structure. It’s a cost-effective solution for building a modern mushroom farm suitable for standard equipment.
- Rooms in Building: The most common system for large-scale projects, this uses sandwich panels to construct the rooms within an insulated steel building. Although requiring a higher investment, it offers lower operational costs and better climate control.
Planning
Mushroom quantity
Having a clear understanding of the potential volume of mushroom sales in your region is crucial. Mushroom production has certain fixed costs that aren’t significantly dependent on the size of the operation, meaning that the project’s feasibility can substantially improve as you scale up. Fixed costs are for instance filling and emptying machines, pumps for watering and cleaning. Coldstore, loading pitt, outside area, infrastructure for power and water, engineering permits and more.
Substrate System
Mushroom substrate is typically produced from straw and chicken manure. The straw functions as fuel and a carbon source for mushrooms, supplying necessary cellulose. Straw contains both cellulose and lignin, though only cellulose can be utilized by the mushrooms. The composting process breaks down the lignin’s protective layers with ammonia, thereby making cellulose accessible. This explains the use of chicken manure, a primary source of ammonia and nitrogen which is crucial for mushroom growth.
The initial phase of mushroom production involves converting straw into a usable form, carried out in bunkers with aerated floors. The resulting material is known as phase 1 compost. This compost is subsequently de-ammoniated and pasteurized in insulated tunnels, where the material is placed on grids to allow forced air circulation. This sterilized and pasteurized compost, termed phase 2 compost, is highly susceptible to infections and therefore non-transportable.
The phase 2 compost is then inoculated with mushroom spawn under rigorous hygiene conditions in another tunnel. Here, the spawn expands until it fully colonizes the material. This substrate is then cooled down and prepared for transport. The final product, known as phase 3 substrate, is entirely odorless and free of ammonia.
However, it’s essential to note that the initial composting process generates substantial amounts of odor and ammonia emissions. In populated areas, the composting exhaust air must be treated before release to prevent causing environmental nuisances.
Once the production volume is established, you can choose the appropriate substrate system. Three systems are available:
- Phase 3 Ready Substrate in Bulk or Blocks: Substrate production involves certain fixed costs, unrelated to the size of the operation. The organization needed for procuring materials and running the substrate factory represents a partial fixed investment. Moreover, substrate production can lead to emissions, including ammonia and odor, necessitating a careful choice of location and sufficient volume.
- Phase 1 Substrate Processed into Phase 3 in Own Tunnels: If there is regional substrate production and a significant volume is desired, purchasing phase 1 could be an excellent choice. For most compost producers, increasing phase 1 production is easier than scaling up phase 3 production, making phase 1 purchase a potential necessity. In this scenario, the mushroom production site would require phase 2 and phase 3 tunnels. This system will emit odor and ammonia, which can be significantly reduced with appropriate equipment.
- Own Substrate Production: With a sufficient volume, self-substrate production can be extremely feasible. Many global projects involve substrate production and mushroom production occurring on the same site. However, if it’s possible to maintain some distance (a few kilometers) between the two locations, it would be a better choice considering the risk of phase 2 compost infection from the mushroom farm.
Labour availability
Beause mushroom production is labour intensive it’s important to understand if the region has sufficient human resources. If this is not the case than building housing can be investigated as a solution.
Consultant Role
Mushroom cultivation is a highly specialized industry that necessitates a vast knowledge base for successful operation. At Serca, we provide expert guidance and utilize our extensive network to identify the most suitable companies to carry out your project.
System Selection
Being a knowledge supplier rather than an equipment supplier, Serca is capable of independently identifying the optimal system for your specific needs. Based on minimal figures, we can discern the most suitable system for your operation. Occasionally, this might require a bit of investigation; however, most of the time, simply by considering the quantity and location, we can logically determine the most effective system.
Business plan
Serca has tons of experience in making business plans. We can make professional and complete business plans based on research experience and up-to-date knowledge of the industry.
design
During the design phase, careful consideration is given to the smallest details, such as hygiene, daily operations, logistical movements, and logical construction choices.
At Serca, we have extensive experience collaborating with local architects. We understand their requirements and can supply them with all the necessary information, calculations, and drawings needed to complete the job. Having participated in building permit procedures all over the world, from Korea to Germany, and from Kazakhstan to Ireland, we have a thorough understanding of how to navigate this stage of the project.
Supplier Selection The mushroom industry is diverse with numerous equipment suppliers. Some specialize in a narrow range of machinery, while others offer turnkey solutions. The optimal mix of suppliers varies for each project. The best choice for a project in Germany may differ from that in India, taking into consideration variables like labor costs and local infrastructure.
Local Collaboration At times, engaging local companies for construction and specific equipment can be cost-effective. It can also confer advantages in terms of warranty and maintenance. Serca is adept at collaborating with both specialized mushroom suppliers and local firms. If a local company undertakes the construction, Serca can fortify the project by providing the necessary design and technical assistance to ensure maintained quality.
Grower Training In addition to technical support, Serca also offers operational assistance. This can be achieved by identifying a grower and sourcing the right consultant to initiate the project.