Production of CornWall® StoneCycling X Circular Matters

How it's madeCornWall®

The sustainable alternative for interior wall cladding.

To overcome the problem of scarcity, we search for raw materials that are found everywhere in abundance. Circular Matters leverages the power of plants to create materials that replace fossil-based plastics and resins.

Primarily made from corn waste, CornWall is the sustainable alternative for interior wall cladding.

Converting crops into resources

Maize is the most common crop on the planet: it's everywhere! Farmers separate corn used for human consumption from the cob, but the cob has no nutritious value and most often burned as biomass.

Corn cobs that would otherwise degrade on the field or burned as biomass (in both cases, carbon locked in the biomass gets released) are collected and dried.

World wide, there's an almost unlimited supply of this material available as corn is one of the most commonly grown cobs on the planet. There's a huge opportunity to utilise this material for other purposes.

When the cobs are dry, a specific shredding process produces the biomass that becomes the main ingredient for CornWall.

Circular Matters and StoneCycling Launch CornWall®

From Cob to CornWall

Designing with Nature

In our laboratory, we’re constantly investing time and effort into developing new recipes.

We have a standard collection featuring various colours and textures. For projects exceeding 1.000 m², we also offer Custom Made solutions. Adjustments can be made to colour, texture, and size, creating the perfect wall finishing material for your project.

Product Design

The material is mixed with pigments and other plant-based biomass to create a > 99,5% plant-based recipe. Less than 0,5% pigments are added to the mix to produce the colours. These pigments are not yet bio-based, but they are biodegradable.

The mix gets pressed though high pressure and by adding heath. A maximum temperature of about 150 degrees Celsius is required. This heat is created by using energy from the solar panels on the roof of the production facility, making the production process carbon neutral. All the energy used in the production process comes from the solar panels on the roof.

After pressing the material, the CornWall is cut into the right size and gets a biobased waterproof coating.

CornWall is packed in boxes and placed on a palet. Since the material is thin (about 4mm) and super light (about 5kg per m2), transportation of the material is much more efficient when compared to other materials such as ceramics or HPL.