Malai
Malai is a circular material made from waste coconut water obtained after the removal of the white flesh of a mature coconut. It is made from entirely organic and sustainable bacterial cellulose, grown on agricultural waste sourced from the coconut industry in Southern India.
Production process
The rescued coconut water is sterilized in vats, thus creating an energy-rich, entirely natural nutrient upon which a bacterial culture can feed. It is combined with bacteria to ferment for 12 to 14 days. One small coconut-processing unit can collect 4000 litres of water per day, which can grow 25kg of cellulose.
This material then undergoes refinement by the addition of natural fibres, gums and resins, which may then be formed into flat sheets or moulded seamlessly into 3D structures. For dyeing, a patented cold-batch method is used.
Currently, the production is in a small pilot manufacturing unit with a capacity of producing ca. 200 m sq. per month. Plans for sustainable upscaling are underway.
Material properties
Malai is a light, flexible, and durable material comparable to leather or paper. It is water resistant, and as it contains no artificial chemicals, it does not cause any allergies, intolerances or illness. It is hygroscopic and has quite a bit of shape memory.
It can be produced in sheets (with a range of thicknesses). Plus, Malai Eco has also developed a process whereby three-dimensional objects can be created using a moulding technique (technology under development).
Malai is available in a range of colours achieved through mordant-free, plant-based dyes, and it can develop a soft sheen or patina over time.
Due to its natural composition, it is sensitive to humidity, much like paper or leather. Hence, applying a thin layer of beeswax or coconut oil (to continue Malai’s completely vegan credentials) to the surface is suggested, especially during hot, dry weather or after cleaning.
Malai lasts anything from 4 to 8 years if properly cared for.
It can be used to make light footwear, accessories and interiors.
Circular features
Malai Eco works with local farmers and processing units by collecting their waste coconut water and re-purposing it. The water would otherwise be dumped, causing damage to the soil due to its acidity.
Raw Materials
- Waste coconut water
- Cellulose-forming bacterial culture
- Plant-based dyes
Afterlife Plan
Biodegradable/compostable (takes 3 months to fully biodegrade in natural conditions).
Supplier
Image source: Malai
