Production SOPs

Phase-II Pasteurization Tunnel operations require strict temperature and oxygen management to eliminate ammonia and pathogens.

• Ramp-Up: Gradually increase temperature to 57°C over 12 hours.
• Pasteurization: Maintain strictly between 57°C to 60°C for 6 to 8 hours. Do not exceed 61°C (kills beneficial thermophilic fungi).
• Conditioning: Lower to 48-52°C and hold for 4 to 6 days to clear ammonia (target < 10ppm).
• Cooldown: Rapidly cool compost to 24-25°C before spawning.

Proper inoculation requires absolute sterile conditions to prevent green mold (Trichoderma).

• Sterile Handling: Workers must use IPA (Isopropyl Alcohol 70%) on hands and tools. Masks and fresh aprons are strictly mandatory.
• Grain-to-Compost Ratio: Use 0.5% to 0.7% spawn by weight of wet compost (e.g., 50-70g spawn per 10kg compost).
• Mixing: Ensure uniform distribution of grain. Top dress lightly to accelerate surface colonization.
• Incubation: Maintain room temperature at 24°C with high relative humidity (90%+) and high CO2.

The casing layer provides water storage and induces pinning. Poor casing leads to stroma formation.

• Material: Coir pith + Farm Yard Manure (2-year old) + Chalk powder.
• pH Balance: Adjust strictly to 7.5pH using Calcium Carbonate (chalk mitti).
• Formalin Treatment: Treat raw materials with 2-4% Formalin solution. Cover tightly with a tarpaulin for 48 hours to pasteurize.
• Off-gassing: Uncover and rake repeatedly for 24-48 hours until all traces of formaldehyde smell are gone before application.

Biological contamination is the primary cause of crop failure. Zero-tolerance hygiene must be enforced.

• Footbath Protocols: Install 2% Formalin or Bleach footbaths at every entrance. Replenish daily.
• Fly-Net Specifications: Install 40-mesh nylon screens on all vents, exhausts, and doors to prevent Sciarid and Phorid fly entry.
• Waste Disposal: Spent compost and infected bags must be immediately sealed in plastic and moved at least 500 meters from the growing area.
• Sanitization: Spray 0.5% Bleach solution on floors and corridors twice daily.