Since 1996, Pilzgarten Ltd from Helvesiek, in the Elbe-Weser triangle between Hamburg and Bremen, has been producing up to 12 tons of mushrooms per week from sustainable and organic raw materials. These are mainly king trumpet mushrooms, for whose Germany-wide market launch Pilzgarten received the CMA Innovation Prize in 2001. But there are shiitake as well, the mushroom with which everything began 26 years ago.
And now, in Helvesiek, another big step is being taken: Pilzgarten is the first mushroom cultivator to succeed in integrating substrate previously used for growing organic mushrooms into the production process of new substrate. Its sister company BioMycoTec is involved in this.
The mushroom cultivation: Packing substrate bags and harvesting king trumpet mushrooms.
Producing one's own substrate
Producing one's own substrate, has always been an integral part of the Helvesiek-based company. "While other growers in the fine mushroom industry will source their substrates from external producers - one of the largest is in the Netherlands - we take a much shorter, in-house route. It is better for the environment because it avoids unnecessary transport runs. And it is better for Pilzgarten's customers, because they can rely on reliable delivery while maintaining the usual high quality standards," says the company management.
Of course, when after several months the mushrooms erupt from the substrate blocks in the greenhouse tunnels, you don't stop and consider the finely tuned processes that went before. But these processes are essential for the growth and quality of the mushrooms. For each mushroom variety, there is a specific substrate recipe on which the mushroom will thrive. And this is where the mushroom garden team comes in; it knows its stuff.
20 percent of the substrate goes back into the cycle
With its
own substrates, Pilzgarten has an enormous advantage over its competitors. Owner Torsten Jonas (r), however, is not satisfied with maintaining the status quo. That is why he developed a process in which 20 percent of the harvested substrates are reused for substrate production. "This saves raw materials and energy and it also has a positive effect on fungal growth. The result is a proprietary and even more unique cycle that once again underscores the company's innovative strength," Jonas says.
Less gas, more sun
To produce the substrates, Pilzgarten primarily needs both steam, which is generated using natural gas, and of course electricity to run the machines. The search for ways to reduce energy consumption resulted in a new boiler house that uses about 30% less natural gas and water. Its reverse osmosis system requires less chemical processes to provide the boiler water. The photovoltaic system covers 20 percent of the electricity needs of substrate production.
"Those who know Torsten Jonas' team will know that this is by no means the end. Behind closed doors, development is already moving forward again."
Torsten Jonas (r) is managing director of Pilzgarten and BioMycoTec Ltd. Together with his colleagues Wilfried Holst (l) and Christian Oertels (m), he was recently at the Hessian Mushroom Days.
The Pilzgarten in figures
Founded in 1996
60 employees
11 hectares of farmland
5,000 m² substrate production area
3.600 m² greenhouse area
8 - 12 tons of organic mushrooms per week
Pictures: Pilzgarten GmbH
For more information:
Pilzgarten GmbH
Fabrikstraße 12
27389 Helvesiek
+49 4267 933 117
hjonas@pilzgarten.de
www.pilzgarten.de