Feasibility study into methods for improving the scalability of MICP (Microbially Induced Calcite Precipitation) for the production of Low carbon Precast Tiles and internal cladding systems

Cresco uses biotechnology to manufacture low carbon panelling materials for the construction industry. In 2020 Gypsum plasterboard caused 3.5% of the UK's greenhouse gas emissions. We develop sustainable and circular alternatives to interior panelling products. Using a bacterial bio-manufacturing process, we produce low carbon bio-composites utilising industrial waste.

Our material is naturally water and fire resistant, hard wearing, utilises high percentages of waste material (60-90% wt). The entire manufacturing process happens at room temperature. Being able to manufacture without the need of high energy heating processes is where the majority of the carbon savings occur compared to traditional alternatives. As the bacterial process is naturally carbon negative, it is even possible to go carbon negative if the chemical feedstock is supplied through green energy chains.

The material shows great promise for non-structural internal panelling applications which would have a high impact on the embodied carbon of a building.With the growing green construction materials market (estimated $940 Billion by 2030), low carbon off the shelf solutions promise commercial success and are essential if we are to tackle the 10% of global CO2 emissions caused by the manufacture of construction materials.

Having worked on optimising our process for panelling the past year, the market blocker is neither demand, nor material properties, but instead optimisation needed at the moulding stage for commercial scalability. Cresco Ltd. and the Living Construction Research Group (HBBE, Northumbria) will assess the feasibility of 3 different methods for improving the energy and resource efficiency during moulding. This will allow the business to make a decision around which process to select for scaling and develop further through a subsequent larger project. The project will act as a catalyst between Cresco and HBBE to aid the development and delivery of a new and disruptive sustainable biomanufacturing process which would pave the way for implementation of a scalable manufacturing system to produce low carbon bio-composite panels.