Project Title: Dungwood: Transforming Cow Dung into Sustainable Materials
Role: Lead Designer & Material Innovator
Nature of the Project:
This project revolved around the exploration and development of Dungwood, a sustainable, biodegradable material made from cow dung. The goal was to create a bio-composite that could serve as an eco-friendly alternative to traditional wood and engineered boards like MDF. The project aimed to address environmental challenges like methane emissions and deforestation by repurposing surplus cow dung, a major byproduct of the dairy industry.
Project Duration:
October 2021 – May 2022
This project was part of a 2.5-year-long material innovation journey as a Master's graduation project.
Problem Statement:
With over 300 million cows in India alone, the dairy industry produces around 3 million tons of surplus cow dung annually. Much of this goes unused, contributing to methane emissions and environmental degradation. The aim was to find a solution that could turn this surplus waste into a valuable resource, simultaneously addressing environmental concerns and providing sustainable alternatives to deforestation and methane emissions.
The Central Question:
“How can we repurpose surplus cow dung to reduce methane emissions, prevent deforestation, and create a sustainable alternative to wood?”
Project Journey
The Genesis
The journey of Dungwood began in October 2021 as a graduation project, driven by a desire to innovate around sustainability. I was fascinated by the potential of cow dung, a material often disregarded as waste but rich in unique properties such as anti-fungal, water-repellent, and thermal insulating characteristics. The goal was to turn this seemingly worthless material into something with global relevance an alternative to wood in the Indian and Dutch markets.
Material Exploration
Why Cow Dung?
Cow dung is far more than waste. It contains over 50 million microbes per gram, making it naturally anti-fungal and thermally insulating. It is also lightweight, water-repellent, and biodegradable properties that made it ideal for material innovation.
Prototyping & Iteration
Throughout the project, over 30 samples were developed using cow dung as the primary ingredient. The mantra was simple: Do, Reflect, Do Again. This iterative process allowed for constant refinement and exploration, with each version offering new insights into the material's potential. I realized early on that collaboration with experts across different fields was essential to unlocking the material’s full capabilities.
Key Collaborations
The success of Dungwood was built on the collaboration between a diverse group of people, from local villagers to top university professors. Key contributors included:
Local Farmers: Assisted in sourcing raw materials (cow dung).
PhD Students from TU Delft & Professors from Wageningen University: Helped with research and testing.
Microbiologists from Gujarat Vidyapith: Provided insight into the microbial properties of dung.
CEO of Avani Organics: Guided eco-friendly production.
ATIRA, Ahmedabad: Assisted in developing heat-pressing techniques for material production.
Production Process & Testing
Production Techniques:
Heat Pressing: Dungwood uses no synthetic binders; instead, the lignin in cow dung serves as the natural binder when heat-pressed.
CNC & Laser Etching: These precision techniques were used to test the material’s texture and aesthetic appeal, allowing for neat finishes that made Dungwood commercially viable.
Natural Pigmentation: Sugarcane bagasse was added to help Dungwood absorb natural pigments more effectively.
Flexural Strength: Dungwood exhibited a flexural strength of 30 MPa, comparable to pinewood (40 MPa), making it an ideal substitute for wood in construction and furniture applications.
Moisture Resistance: Testing showed that dungwood could degrade quickly outdoors if not waterproofed, pushing further experimentation with waterproofing techniques.
Nutrient Test: After decomposition, Dungwood enriches the soil with vital nutrients like potassium, nitrogen, and phosphorus, making it not just a sustainable product but also an eco-friendly one.
Dungwood’s Unique Selling Proposition (USP)
Key Features:
100% Biodegradable: After its useful life, Dungwood decomposes naturally, enriching the soil and promoting circularity.
Flexural Strength of 30 MPa: Comparable to high-quality wood, Dungwood offers structural integrity for use in construction, furniture, and design.
Customizable Finish: Dungwood’s strength, weight, color, and texture can be customized for various applications, from interiors to art installations.
Thermal Insulation & Antimicrobial Properties: Ideal for breathable living spaces and protective environments.
Potential Applications of Dungwood
Construction & Building Materials:
Dungwood can be used for walls, ceiling panels, and insulation materials, offering eco-friendly alternatives to traditional wood. Its thermal and antimicrobial properties make it especially suitable for sustainable living spaces.
Furniture:
Dungwood’s strength and flexibility make it ideal for tables, chairs, and cabinetry, offering a chic, tactile design that can replace MDF and particle boards.
Acoustic Panels:
The porosity of Dungwood makes it an excellent sound-absorbing material, suitable for room dividers and soundproofing in offices and public spaces.
Art & Design:
Dungwood's tactile nature, combined with customizable textures and finishes, makes it perfect for installations, art pieces, and sensory designs.
Key Milestones & Achievements
Scaling Up Dungwood
One of the project's most significant successes was the scaling of Dungwood from a 5x5 cm sample to a 220x90 cm panel. This achievement marked a crucial step in proving the material’s viability for larger, more practical applications.
Partnerships & Recognition
MoU with the Government of Gujarat: Micro-factories for Dungwood are set to be established across rural dairy villages, creating jobs and promoting sustainability.
Dubai Expo Presentation: Fully funded opportunity to showcase Dungwood, which attracted significant investor interest.
What Design Can Do (Amsterdam): Pitched as a Biodesign Pioneer, garnering attention from IKEA’s R&D team.
Grand Start-up Conclave (Hyderabad): Presented the project to farmers and entrepreneurs, raising awareness about the surplus dung issue and offering a scalable solution.
What Do People Feel About Dungwood?
Handling Dungwood evoked a variety of emotions from participants. Smooth samples felt comforting, while sharper textures made participants uneasy. Non-uniform textures were often considered more natural and beautiful, creating a sense of warmth and connection. Overall, the material's earthy texture and tone made participants feel grounded, with feedback frequently including words like "comfort," "warmth," "earthy," and "nurturing."
Aligning with Global SDGs
Dungwood contributes to multiple United Nations Sustainable Development Goals (SDGs):
SDG 12 – Responsible Consumption and Production: Promotes sustainable production by transforming waste into valuable materials.
SDG 13 – Climate Action: Helps reduce methane emissions from surplus dung.
SDG 15 – Life on Land: Protects forests by providing an alternative to deforestation.
SDG 8 – Decent Work and Economic Growth: Creates jobs
Government Partnerships: Signed an MoU with the Government of Gujarat to set up micro-factories in rural areas, providing local employment and reducing environmental footprints.
Global Exposure: Presented at the Dubai Expo and “What Design Can Do” in Amsterdam, garnering interest from investors, including IKEA.
R&D Growth: Continued development with top research institutions, expanding the potential for Dungwood’s applications globally.
Emotional Response to Dungwood
During user tests, participants expressed an emotional connection to Dungwood’s tactile nature. They used words like comfort, warmth, earthy, and nurturing to describe their experience with the material. The natural, non-uniform textures were viewed as authentic and beautiful, evoking a positive, grounded response.
Future Vision: Tiny House with Dungwood
Looking ahead, Dungwood’s potential expands beyond furniture and decor. By 2024, the aim is to construct the world’s first Tiny House using Dungwood. This project will showcase the material’s versatility and scalability, offering a sustainable solution to the housing crisis in Europe, while addressing methane emissions from dairy farms.
Lessons Learned
Material Innovation is Iterative
The project taught me that material innovation is a continuous process of exploration, reflection, and collaboration. Dungwood evolved from small-scale prototypes into a fully scalable material with vast applications, thanks to an iterative approach and collective effort.
The Power of Collaboration
Collaborating with local artisans, scientists, and industrial partners was key to the success of the project. Each person involved brought unique expertise, proving that innovation thrives when knowledge from different fields is combined.
Conclusion
Dungwood represents the future of sustainable material innovation. By transforming waste into a valuable resource, it provides a practical, eco-friendly alternative to traditional materials like engineered wood. Through this project, I learned that every material has the potential to tell a powerful story one of sustainability, innovation, and a shared vision for a better future.
This is just the beginning. The journey of Dungwood continues to grow, transforming both the material and the world around it.