Our micellar production process has been developed with more than 20 years of experience in the manufacturing industry and is divided into 7 main stages that enable us to achieve an unmatched level of quality control and efficiency.
"1. Raw material and supplier selection
We start by selecting the best grains and additives from suppliers that are rigorously quality tested to ensure that all our quality parameters are met.
All raw materials used in production are subjected to strict controls determined by our Quality Department and accepted into the facility. All inputs are analyzed to ensure they are free from foreign organisms (contaminants) that could affect the winding speed of the micelle.
It is essential to use pure, natural and fresh cultures in order to produce superior micelles.
Fimycel's modern and rich culture collection, located in a separate facility from the production building, consists of pure strains frozen below C -80 used to produce our micelles.
Before being used in production, all strains are approved by fimycel's expert microbiologists after all tests are completed.
2. Preparation of Liquid Mother Culture
Every Fimycel product goes through a carefully arranged series of steps at all stages of production
The relevant pure culture for each batch of product is carefully "awakened" by removing it from the Culture collection where it is stored for a long time at -80 C.
It is produced first in petri dishes, then in a small tube and finally in liquid form by expert trained personnel in computer-automated, fully sterile, state-of-the-art fermenters, untouched by human hands and by carefully controlling all stages.
The liquid main culture obtained from fermenters in which all biological and chemical parameters are realized in full control with its biological enzyme production experience and infrastructure, has the purest, strongest and concentrated form that carries all the characteristics of the fungus that is its source.
In classical solid main culture production; The strain in the test tube is manually grown one step and the main culture is obtained. While the micelle varieties are obtained by reproducing the main culture one more step, it is very difficult to control the purity of the micelle in these transition stages.
A small impurity and contamination that will occur in these stages may cause yield decreases and even mold when passed to the micelle compost. With the use of liquid mother culture in the production of our micelles, minimum mold and maximum yield is obtained during planting.
Another advantage of using liquid mother culture is its ability to be planted directly into compost without the need for a carrier grain medium in case of using fully sterile compost. With the use of liquid culture in this way, the germination time is considerably shortened and the first germination begins within 24 hours. Thus, efficiency increases by decreasing the incubation time.
3.Baking the grains and preparing the mixture
The third stage is the section consisting of large and different mixers in which the ideal moisture content is provided by cooking without spoiling the grained structure of the grains, and other additives are added to increase the winding speed and efficiency of the micelle.
In the fourth stage of the process, the grains, whose moisture balance is provided by cooking and enriched with additives, are min. They are sterilized for 2.5 hours and purified from all bacteria, mold and yeast.
Chemical and biological tests are repeated for quality assurance in each batch of products at the exit of the autoclave.
Fimycel sterilization process; It has the features that we have completely developed with our own R & D studies and enables us to produce flexible solutions that can meet the requests of all our customers, big or small.
5. Vaccination and clean room
At the exit of the autoclave, the grain mixture, which has completed its quality tests and sterilized, is inoculated in clean rooms, in sterile breathable bags with F0 Liquid Mother Culture (LMC) and mixed with automatic mixing machines.
Clean room where vaccinated; It is covered with HEPA filters and disinfection units specially designed for contaminants, and it is a completely sterile area. The teams working in this field are experts and specially trained people.
These applications zero the risk of contamination of the product. Sanitary checks are regularly carried out in "Clean areas" to ensure that the production does not contain any contamination.
The bags prepared by inoculating with Liquid Mother Culture (LMC) are transported to the growing chambers where the amount of heat, light, humidity and oxygen are controlled by automation for maximum micelle development and left to fermentation for a period of several weeks (depending on the type of fungus).
The process is followed by regular daily checks during the incubation period by our authorized personnel.
Bags, whose incubation period is completed, are transferred to cold storage for complete growth and product stabilization. All products must pass our strict Quality Assurance protocols before being transferred to cold storage inventory.
At this stage, as in the other stages of the Fimycel production process, we work with the utmost precision to ensure that our products are products you can trust, without skipping any details.
7. Storage and Transport
The bags, whose incubation period is completed, are transferred to cold storage for complete growth and product stabilization. All products must pass our strict Quality Assurance protocols before being transferred to cold storage inventory.
Fimycel products are stored on shelves in our cold air warehouses at +2 degrees until they are delivered to the customer. Before shipment, samples are taken by Quality Control from the selected bags with the sampling method, the activity of the micelles is passed through strict laboratory tests, the products that are approved are labeled one by one and defined to ensure product traceability.
For each batch of products entering our cold storage, necessary amount of witness samples are kept throughout the shelf life of the product. The purpose of this witness sample system is; It is to ensure product safety with the most accurate information about growing conditions and maximum customer satisfaction by testing different parties in different producer environments.
The products, which are visually checked one by one just before they are shipped to the customer, are now ready for shipment. Our shipments to all regions are carried out with cold chain transport vehicles and our customers' own vehicles.