MALAI, From Coconut Waste to Conscious Design

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Malai was born in 2017 following Zuzana’s graduation project The Invisible Resources from 2014. It began with exploring the potential of using a traditional bacterial cellulose growth process used in the Philippines, where “Nata de Coco” (the Filipino version of this substance) is a key element in the food industry - for creating biocomposite materials for daily objects.

In 2017 the founders moved to Kerala - a region dedicated to coconut cultivation, and began working full-time on developing Malai for various applications. Today, the brand is headquartered in Cochin (Kerala, India) and also operates from Slovakia. It has a team of 10 people working in production, research and development, marketing, sales, and design. Malai collaborates with a broad network of experts in microbiology, materials science, chemistry, mechanical engineering, and business development.

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Malai's Material

Malai is an innovative material made entirely from organic and sustainable bacterial cellulose, grown on agricultural waste from the coconut processing industry in southern India. It is a flexible and durable solution, comparable to something in between of leather and handmade paper. It is water-resistant and, since it contains no harmful artificial substances, it does not cause allergies, intolerances, or illnesses. It is a fully vegan and compostable product and if properly cared for, can last between 4 and 8 years (or more).

Thanks to its composition, Malai is sensitive to humidity, so the company recommends applying a thin layer of beeswax (transparent shoe polish or furniture wax) or coconut oil (to maintain a vegan approach) to the surface, especially during hot and dry periods or after cleaning. If it gets dirty, just use a damp cloth and let it air dry – avoid using a washing machine, dryer, or iron. The team also recently introduced a three step material care kit.

The name "Malai" refers to the creamy pulp of the coconut, and it is the water from mature coconuts (a byproduct of pulp harvesting) that feeds the bacteria during the cellulose production process. This cellulose is then harvested and refined into the finished material.

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The Technology

Malai works closely with coconut farmers and processing units in southern India, who produce large amounts of coconut water waste after removing the white pulp from mature coconuts. Normally, this waste is discharged into the sewage system, causing water pollution and soil acidification of the surrounding soil. A small coconut processing unit can discard up to 4,000 liters of this water per day. Thanks to Malai, this water is recovered and sterilized to become a natural and energetic nutrient for the bacterial culture. The fermentation process lasts between twelve and fourteen days and results in a sheet that is then refined. This is enriched with natural fibers, gums, and resins to create a stronger and more flexible material that can be transformed into flat sheets of various thicknesses and textures, or shaped into seamless 3D structures. The material can be dyed and may develop a sheen or patina over time. Malai uses only plant-based dyes sourced from India and a patented cold-dyeing method.

Currently, Malai operates a small pilot production facility with a capacity of about 200 m² per month. The team is working to scale production in the most sustainable way possible, collecting and validating data at every stage of the process.

To discover more about this material, visit the official website and follow Malai on Instagram!