Pilzland
About Pilzland
Pilzland is the largest mushroom producer in Germany, with four production sites across three federal states. For over 30 years, Pilzland has relied on GTL’s expertise. With a total of 15 head filling machines, more than any other client, and multiple major expansion projects, Pilzland is a loyal and forward-thinking partner.
The Challenge
Pilzland wanted to establish a new production facility in Schwaigern. Since the company already had an existing site in Bavaria, they purchased land and immediately applied for a building permit for a similar structure. This allowed for speedier construction but imposed constraints: the building design was fixed, so our systems had to be adapted to fit.
The goal was clear: achieve maximum production with minimal personnel. Smart choices were required, especially given the growing scarcity of skilled labor.
Our Solution
GTL developed a phased model for the new facility:
- Phase 1: 4 nursery rooms + 4 harvesting rooms
- Phases 2 & 3: identical to Phase 1
- Total production: 60 tons of mushrooms per week
Key Innovations and Benefits
- Tilt Rack System: Fully adapted to the existing building structure
- Separate nursery rooms: Optimized for construction, hygiene, and sustainability. No pickers or harvesting machines enter these rooms, reducing disease risk. No steaming required, saving time, costs, and providing environmental benefits
- Ergonomics & working posture: Tilt racks ensure optimal working position and improved labor conditions
- Flexible packaging solutions: Mushrooms are harvested in the cell, transported outside, and packaged there. This reduces disruption and future-proofs production for changing consumer packaging
- Compatibility with conventional airflow: Our system fits into traditional rooms, so building design did not need modifications
MycoSense: Technology in Practice
This was Pilzland’s first new-build project fully integrating MycoSense. This 3D scanning technology provides real-time insight into mushroom growth and quality, allowing optimal management of production and labor deployment.
Spotlight – on the bed:
- Monitor growth
- Identify mushrooms for harvesting
Scanbox – on the belt system:
- Detect color
- Identify contamination
- Check shape and size
This combination of Spotlight and Scanbox gives Pilzland full control over cultivation, both in the room and during transport, leading to higher efficiency, better quality, and less waste.
Results
- A state-of-the-art production facility with cutting-edge technology
- 60 tons of mushrooms per week in Phase 1, with potential to expand further in Phases 2 and 3
- A sustainable, flexible, and future-proof system, fully aligned with modern mushroom cultivation challenges
- Complete assembly and start-up by GTL staff, from start to finish
Collaboration
The partnership with Pilzland is an example of how long-term collaboration drives innovation and success. For over three decades, we have worked together to implement the most advanced solutions for mushroom production. This project demonstrates how we continuously raise the bar together.