View on Polish compost production

The Polish mushroom sector is developing fast. The demand of phase 3 compost is rising. More fully grown compost means faster schedules en more mushrooms. The positive developments in Poland create a constant growth of the mushroom production and plays an important role on the European market. Due to strong growth in demand for phase 3, the producing companies encounter a number of (logistical) problems.

By Nikodem Sakson, consultant, Poland

Compost production in Poland is the most modern and constantly developing part of the mushroom production chain. This year, mushroom production in Poland is estimated at 175 000 tons and rising. The mushrooms are mainly grown in so-called satellite systems. There are currently 23 compost production companies that produce green compost at a rate of between 160 tons to 4000 tons per week. Two new compost production companies are being built at the moment; one of them is expected to start production late this year.

At present three compost production companies are engaged in the production and sale of phase 3 compost, later this year two other companies will start production of fully grown compost. 100 to 300 tons of compost is currently imported from Germany, the Netherlands and Belgium.

All the compost production companies comply with the legal requirements of environmental protection, obligatory under Polish law.

The raw materials used in green compost production are mainly wheat straw, rye straw, chicken manure both with straw and without straw, and industrial gypsum. Horse manure is used on a small scale. The entire production of phase I takes place on aerated floors using the half indoor or full indoor system.

Pasteurization (phase II) as well as phase III is carried out in tunnels, which are equipped with aerated floors. The compost is removed by using loaders or placed on nets and winched out. The tunnels are loaded using hoppers. A specific feature of compost production in Poland is that phase II and III compost is sold in pressed blocks covered with plastic sheeting. The blocks with phase II composted are inoculated with mycelium to the orders of specific mushroom growers. For phase III several compost production companies offer basically only one variety.

Mechanical filling is done on a small scale basis and takes only place in the large mushroom production companies.

Seven main problems

So, let’s look at the main problems facing the Polish compost industry.

1. Compost production companies are not located near the mushroom production companies. The dynamic development of mushroom production in East Poland, with production mainly destined for Russia, and the lack of investment in compost production in this region means large quantities of compost have to be transported from other regions in Poland such as Slask or Lask, distances of up to 400km! This raises production costs and creates logistic problems. Even more so,  as parts of the road network are unsuitable for heavy transport in the summer. This situation is unlikely to change for the next few years. One of the risks of the long transport distances is a temperature increase in the phase III compost.

2. The basic materials like straw also have to be transported from further away. The growth of production is a result of increasing demand. The straw is collected in high pressed blocks. This also contributes to higher production due to the longer haulage and higher fuel costs. This situation will remain unchanged for the next few years.

3. The necessity of development of phase III compost. Related to the better equipped mushroom growing companies, the increasing demands placed on mushrooms destined for export, and more skilled and better qualified Polish growers, the demand for compost phase III is expected to intensify. At the same time all the compost producers are aware that due to the Trichoderma harzianum  danger, the production of this compost must be carried out in highly equipped plants, which guarantee a fully controlled process. This involves high investment costs and slows down the investment process. The pressure of the market on purchasing phase III compost will grow.

4. Imported compost. The shortage of phase III compost on the Polish market has resulted in its import mainly from Germany, the Netherlands and Belgium. In the beginning, imports were hampered by problems and delays crossing the border. This long waiting time caused the compost to overheat and deliveries were done at a loss. The other factors, which limit imports, are the high transport costs as well as qualitative differences in the imported compost. Consequently, phase III compost is mainly imported to West Poland.

5. Mushroom growers have little opportunity to influence the compost amount. The sale of compost in blocks as well as the seasonal aspects of production means the demand is not satisfied and growers are unable to exert enough influence on the amount of the compost bought. It is especially difficult for the best producers, who use phase III compost and are able to make good use of it.

6. The seasonal character of compost production. Mainly in the Wielkopolska (West Poland) area, where most mushroom production is aimed for processing companies, compost production is taking place in insufficiently equipped plants. As a result in the summer months some compost production companies reduce production to 20-30% of full capacity. This situation hugely influences cost and organization of the production in these companies. It also places heavy stress on the market at the beginning of the season.

7. The large number of clients. An average compost production company serves 150 to 300 customers, resulting in high service costs and preventing proper communication with these growers. Many compost production companies have decided to employ specialists for mushroom production responsible for accounts in certain regions in the country.

Improving the production process

Recently, the discussions in Poland have centred on development of production methods and ways to improve production in order to obtain compost that ensures high yields of premium quality mushrooms.

The development of compost production is carried on in practical activities and must take into account the specific requirements of the country or production region. Poland has to solve the problem of compost production in winter, with temperatures even below –25 degrees centigrade. Problems of varying types of chicken manure. Compliance with environmental legislation and how the customers can use the compost. The basic idea, in indoor systems (production is carried out in sealed rooms under controlled temperature and oxygen conditions) is changed and results in a shorter fermentation. The high investments in phase I compost production will not stimulate the search and implementation of new methods of compost production, especially in Poland.

The main factors which influence how compost affects the final mushroom crop are: the quality of raw materials available on the market and their suitability to the fermentation process, the stability of physical features such as humidity, nitrogen content, pH and compost quantity, enabling the adaptation of quantity and quality supplements, varieties and production technique and technology used by mushroom growers.

The basic challenge facing compost  producers is the search for ways of better control and influencing the production process during composting.