Executive Summary: Mamaku by-product utilisation

Summary of Project and Key Findings:
Ora Innovation NZ Ltd (OINZL) produces mamaku (Cyathea medullaris) extract for skincare applications. As production scales up to the processing of 7 tonnes of raw mamaku per week by 2030, an equivalent quantity of mamaku pulp by-product will be generated. This material, currently returned to land as mulch, contains valuable organic matter, fibres, complex polysaccharides, and residual bioactive compounds. Its composition suggests potential for value-added soil amendment products and or plant-derived cleaning product ingredients.

This Techno-Economic Assessment (TEA) evaluates the technical feasibility, capital and operating costs, and market opportunity for converting mamaku pulp into dried powder or pellets for these downstream opportunities.

Key Findings

• Fully operational OINZL could be producing up to 8,400 kg of dried mamaku powder annually.
  – Flash drying is the most suitable production technology, with a low capital cost (~$15,900) and high throughput (up to 600 kg/h), when compared to convective or freeze-drying
• Freeze-drying, while preserving heat-sensitive bioactives, has very high CapEx and OpEx, making it suitable only for the manufacture of premium/high-value niche product.
  – Estimated manufacturing cost ranges from $16.85–$30.78 per kg, depending on drying technology.
• Soil amendment products in NZ retail from $4.75 to $120 per kg depending on application (bulk agricultural vs professional horticultural use).
  – Break-even sales price for mamaku product: $16.85–$30.78/kg
  – High-value horticultural positioning ($40–$120/kg) offers strong margins
• For the rapidly growing market in plant-derived laundry products – particularly in China, the mamaku extract will likely require further fractionation and further testing for efficacy.

TRL at start of project = 0
TRL at end of project = 1