Method and bioreactor system for producing mycelium biomass

Abstract

A method for producing mycelium biomass. The method comprises obtaining a base media composition and an antifoam solution; sterilizing a mixture of the base media composition and the antifoam solution

Description

TECHNICAL FIELD The present disclosure relates to methods for producing mycelium biomass. Moreover, the present disclosure relates to bioreactor systems for producing mycelium biomass. BACKGROUND As the global demand for animal protein soars, there is a critical need for sustainable and ethical alternatives to conventional meat products. The surge in consumer awareness regarding the environmental impact, health implications, and ethical concerns associated with traditional meat consumption has propelled the rapid growth of the meat alternatives industry. While current solutions have successfully addressed processed meat alternatives such as burgers and sausages, there is a distinct lack of realistic and flavourful whole-cut alternative products such as beef steak, chicken fillets, pork fillets. Existing plant-based products often mimic shredded meats relying on extensive processing and artificial binders, resulting in products that may compromise on health and lack the desired meat-like texture. The resulting products are often unhealthy and texturally unappealing to meat-eaters, with a disordered burger-like structure thus consumers (namely individuals, users) are demanding higher quality, healthier, and more sustainable products. Said shortcomings in the whole-cut meat alternatives pose a challenge to the broader adoption of plant-based diets, particularly among individuals accustomed to the sensory experience of traditional meat consumption. Notably, mycoprotein exhibits significant potential owing to its long fibrous structure (hyphae), good protein quality (Protein Digestibility-Corrected Amino Acid Score, or PDCAAS, often higher than beef), as well as fibre and micronutrients. However, most commercially available mycelium meat alternatives use a fermentation process in which mycelium is grown in a dispersed form, which limits textural appeal and the end-product produced does not satisfactorily replicate meat’s tissue structure from a sensory perspective. Existing submerged mycelium biomass fermentation solutions require additional binding process steps or additives to create meat alternatives, and the end-product result is a less convincing or realistic whole-cut meat alternative. There exist some processes that have made strides in mycelium-based products, but limitations persist. For example, such processes rely on additional ingredients such as eggs for binding, or produce mycelium in a dispersed 'slurry' consistency, which falls short in creating a realistic structure and texture for whole-cut meat alternative products. There exist some other processes that also encounter hurdles with the liquid slurry consistency and resort to a time-consuming dehydration and rehydration process. Therefore, considering the foregoing discussion, there is a need to overcome the aforementioned drawbacks. SUMMARY The aim of the present disclosure is to provide a method and a bioreactor system for producing mycelium biomass to provide more realistic alternatives to meat whole-cuts based on fungal mycelium. The aim of the present disclosure is achieved by a method and a bioreactor system for producing mycelium biomass as defined in the appended independent claims to which reference is made to. Advantageous features are set out in the appended dependent claims. Throughout the description and claims of this specification, the words "comprise", "include", "have", and "contain" and variations of these words, for example "comprising" and "comprises", mean "including but not limited to", and do not exclude other components, items, integers or steps not explicitly disclosed also to be present. Moreover, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an illustration of a flowchart depicting steps of a method for producing mycelium biomass, in accordance with an embodiment of the present disclosure; FIG. 2 is an illustration of a bioreactor system for producing mycelium biomass, in accordance with an embodiment of the present disclosure; and FIGs. 3A, 3B, and 3C are exemplary illustration of mycelium biomass, in accordance with an embodiment of the present disclosure. DETAILED DESCRIPTION OF EMBODIMENTS The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible. In a first aspect, the present disclosure provides a method for producing mycelium biomass, the method comprising: obtaining a base media composition; sterilizing a mixture of the base media composition and the antifoam solution under a first set of parameters; obtaining an autoclaved organic carbon source solution in the mixture; controlling a second set of parameters for obtaining an inoculum culture medium, mixing the inoculum culture medium in the mixture to form a first composition, and; aerating the first composition at a pre-defined aeration rate, wherein the aeration rate is programmed to vary; and harvesting the mycelium biomass from the aerated first composition. The method further comprises obtaining an antifoam solution. In this regard, the method provides a comprehensive and well-optimized approach to the mycelium biomass production, the combination of sterilization, controlled parameters, and aeration helps minimize the risk of contamination, ensuring the purity of the mycelium biomass. This is essential for industries requiring high-quality and uncontaminated mycelium biomass for various applications, such as food production, pharmaceuticals, or biotechnology. In a second aspect, the present disclosure provides a bioreactor system for producing mycelium biomass, the bioreactor system comprising: a vessel configured to obtain a base media composition and an antifoam solution; an autoclave arrangement configured to sterilize a mixture of the base media composition and the antifoam solution under a first set of parameters; a control arrangement configured to regulate a second set of parameters; the vessel configured to obtain an autoclaved organic carbon source solution in the mixture; the vessel configured to obtain an inoculum culture medium; an agitator configured to mix the inoculum culture medium in the mixture to form a first composition; an aeration unit configured to aerate the first composition at a pre-defined aeration rate, wherein the aeration rate is programmed to vary throughout the fermentation process; and a harvesting mechanism configured to collect the mycelium biomass from the aerated first composition. In this regard, the bioreactor system presents a suite of technical advantages encompassing integrated sterilization, automated control, heterogeneous composition, optimized aeration, and streamlined harvesting. The aforementioned components of the bioreactor system operate synergistically, establishing a controlled and sterile environment to produce the mycelium biomass. The bioreactor system maintains a nutrient-rich setting, facilitating efficient, scalable, and high-quality mycelium biomass production. Moreover, the bioreactor system's adaptability to dynamic conditions, coupled with minimized contamination risks, ensures a robust and reliable process from initial production of the mycelium biomass to harvesting of the mycelium biomass. Throughout the present disclosure the term "mycelium biomass" as used herein refers to the mass or collective growth of mycelium, which is the vegetative part of a fungus, consisting of a network of thread-like structures called hyphae. In this regard, the purpose of producing mycelium biomass is to use it as a key ingredient in the development of meat alternatives and to create resource-efficient, and consumer-appealing meat alternatives that closely replicate the qualities of traditional meat products such as for example steaks and chicken breasts, and to offer a more sustainable option for generating protein-rich foods. In this regard, the production of mycelium biomass involves a unique combination of upstream and downstream process. In the upstream process, mycelium is grown by submerged fermentation as a uniquely cohesive, solid but malleable structure in a liquid growth media within a controlled environment and it is harvested and heat-treated followed by a series of post-harvest treatments. Subsequently, in the downstream phase, the heat-treated mycelium is blended with other selected ingredients and subjected to various physical methods to create a final food product, such as steaks and chicken breasts with desirable characteristics. Optionally, the mycelium is grown in the form of a cohesive, non-dispersed biomass, which is solid but malleable, wherein the mycelium biomass has an interconnected hyphal structure. In this regard, the term “cohesive” indicates that the mycelium biomass takes on an aggregated three-dimensional macro-structure or shape in the form of a compact mass, preferably globular. The term “non-dispersed” as presented herein refers to the fact that the mycelium biomass is not dispersed, suspended or disaggregated throughout the fermentation liquid in an aqueous or slurry-like manner. The term "malleable" denotes a state between firm and soft, implying a certain degree of pliability. Additionally, the term “globular” indicates that the mycelium biomass preferably, in some iterations, takes on a rounded shape. The term "hypha (plural: hyphae)" is a thread-like structure that constitutes the basic unit of the fungal body. Notably, the hyphae are the building blocks of the mycelium. The hyphae are the thin, elongated structures that can be either septate or non-septate (aseptate), depending on whether the hyphae have cross-walls (septa) dividing the hyphal cell into compartments. The hyphae play a crucial role in the life cycle of fungi, serving as the means for the fungus to explore its environment, decompose organic matter, and obtain nutrients by secreting enzymes into their surroundings. It will be appreciated that the interconnected hyphal structure refers to the specific arrangement of said thread-like structures in the mycelium biomass in which the connections between the hyphae remain intact to a degree that the biomass maintains a cohesive and non-dispersed shape, and that the interconnection of the hyphae contribute to the biomass’ texture and overall characteristics. Macromorphology and textural qualities of fungal mycelium are influenced when conditions favour either long elongated unbranched growth or shorter, more highly branched growth. The interconnected hyphal structure enables the implementation of a proprietary physical fiber-alignment process. Said process allows for easy and efficient processing of the mycelium into whole-cut products, such as steaks, optionally without the requirement of external binders or other intensive structuring processes such as extrusion. The method comprises obtaining a base media composition and an antifoam solution. Herein the term "base media composition" refers to a nutrient-rich mixture i.e., a combination of various components or substances that are blended to form a unified mixture. Optionally, the specific formulation of the base media composition can vary depending on the requirements of the mycelium biomass being produced. It typically includes a combination of ingredients that support the growth and development of the mycelium biomass. Herein the "antifoam solution" also known as defoamer or antifoaming agent, is a chemical additive used to reduce or eliminate excessive foam during a fermentation process. The composition of the antifoam solution may vary but typically includes antifoaming agents such as silicone-based compounds. Optionally, the base media composition comprises a malt extract, an organic nitrogen source, an organic carbon source, one or more micronutrient sources, growth factors and distilled water. The typical composition of the base media is 30 g / L malt extract, which is derived from malted barley containing sugars, nutrients, and other compounds. The malt extract is a well-balanced and reliable source of nutrients, and it provides the necessary components for the growth of the mycelium biomass. Additionally, the base media composition contains an organic nitrogen source such as soy peptone or yeast extract or other organic nitrogen source at a concentration of 0.78 to 6 g / L, for providing essential building blocks and growth of the mycelium biomass. Moreover, the base media composition comprises the organic carbon source for energy production and for cellular structures. Furthermore, the base media composition comprises one or more micronutrient sources such as iron for use as co-factors in various metabolic processes, and water, as a biological solvent and transport medium for nutrients and minerals. It will be appreciated that the use of ultrapure water ensures a clean and controlled environment for the growth of the mycelium biomass without introducing uncontrolled levels of mono and divalent ions (such as sodium and calcium). This base media composition provides a suitable environment with the necessary nutrients for the growth of mycelium. In this regard, the base media composition is prepared by weighing and mixing the aforementioned ingredients to obtain a mixture therefrom. The inclusion of the distilled water in the base media composition ensures the purity and consistency of the base media composition for the mycelium biomass. The distillation avoids introducing uncontrolled levels of mono and divalent ions, such as sodium and calcium, providing a controlled environment for fungal growth of a desired morphology. The use of the distilled water contributes to the reproducibility and reliability of the method, thereby enhancing the quality and consistency of the resulting mycelium-based products, such as meat alternatives. The method comprises sterilizing a mixture of the base media composition and the antifoam solution under a first set of parameters. The term "sterilizing" as used herein refers to a process of completely eliminating or destroying all forms of microorganisms, including bacteria, viruses and fungi, including spores. The mixture comprises the base media composition and the antifoam solution. The mixture is sterilized to eliminate any potential contaminants and ensure aseptic conditions for the growth of the mycelium biomass. In this regard, autoclaving is used for sterilization. The sterilization involves exposing the obtained mixture to high-pressure steam at elevated temperatures. The combination of heat and pressure allows inactivation of microorganisms, including bacteria, fungi, and other potential contaminants. Furthermore, the sterilization process is carried out under specific process conditions or the first set of parameters. Optionally, the first set of parameters comprises a first temperature in a range of 100°C to 150°C, a first period in a range of 15 minutes to 35 minutes, a first rotational speed in a range of 50 rotations per minute to 1000 rotations per minute. Optionally, the first temperature is in a range of 100 °C, 105 °C, 115 °C, or 130 °C up to 120 °C, 130 °C, 140 °C or 150 °C. Furthermore, the first period is in a range of 15 minutes, 18 minutes, 23 minutes, 25 minutes or 30 minutes up to 35 minutes. Herein the "first rotational speed" refers to a controlled speed at which the mixture is stirred or rotated during the sterilization process, and the first rotational speed plays important role in achieving effective and uniform sterilization of the base media composition and the antifoam solution, the first rotational speed is in the range of 50, 70, 80,100, 110, 120, 130, or 150 rotation per minute up to 140, 160, 180, 210, 225, or 250, or up to 1000 rotation per minute. It will be appreciated that the first set of parameters are essential to the effectiveness of the sterilization process. The aforementioned ranges of the temperature, the period, and the rotational speed are selected to create an environment that is suitable to the mycelium growth while maintaining the integrity of the components in the mixture. The method comprises obtaining an autoclaved organic carbon source solution in the mixture. The term "autoclaved organic carbon source solution" as used herein refers to a stock solution of 40% organic carbon source which is prepared and autoclaved to ensure sterility. The autoclaved organic carbon source solution is introduced to the overall sterilized mixture containing the base media composition and the antifoam solution. The autoclaved organic carbon source acts as a source of carbon for the fungi (namely, mycelium) and facilitates its growth. Moreover, the method comprises controlling a second set of parameters for obtaining an inoculum medium. Herein the "controlling" refers to the adjustment of the second set of parameters such as the second temperature, the second rotational speed, the pH value, and the second period to maintain and manage certain conditions within predefined ranges to optimize the growth and development of the mycelium. Optionally, the second set of parameters comprises a second temperature in a range of 20°C to 42°C, a second rotational speed in a range of 50 rotations per minute to 800 rotations per minute, a pH value in a range of 4.5 to 7, a second period in a range of 2 days to 8 days. Optionally, the second temperature is in a range of 20 °C, 22 °C, 24 °C, 26 °C, 28 °C or 40 °C up to 42 °C. Optionally, the second rotational speed is in a range 50 rpm, 100 rpm, 110 rpm, 120 rpm, 130 rpm, 150 rpm, 160 rpm, 180 rpm, 210 rpm or 225 rpm, (rotation per minute) up to 140 rpm, 160 rpm, 180 rpm, 210 rpm, 225 rpm, or 250 rpm, or up to 800 rpm. Optionally, the pH value lies in a range of 4.5 to 7. Optionally, the second period lies in a range of 2, 3, 5, 6 or 7 up to 3, 4, 5, 6, 7 or 8 days. Beneficially, the second temperature range ensures that the environment is within a suitable range for mycelium growth, the second rotational speed facilitates proper mixing for the mycelium to receive nutrients and oxygen. The pH value is maintained within a range that supports the physiological needs of the mycelium and the specified second period allows sufficient time for the mycelium to proliferate and reach the desired biomass. Furthermore, simultaneously with control of the second set of parameters, the method involves obtaining a meticulous preparation of the inoculum culture medium. Herein the term "inoculum culture medium" refers to a nutrient-rich substrate containing concentrated microorganisms, such as fungal spores or the mycelium. Furthermore the method comprises mixing the inoculum culture medium in the mixture to form a first composition. Optionally, the inoculum culture medium comprises a solution of spores of the desired species, a malt-based complex media in a concentration of 30 g / L with respect to a total concentration of the first composition, an organic nitrogen source in a concentration of 5 g / L with respect to a total concentration of the first composition, the autoclaved organic carbon source solution in a concentration of 7.8 to 30 g / L with respect to a total concentration of the first composition, with respect to a total concentration of the first composition. In some embodiments, during fermentation the organic carbon source is supplemented after it is depleted to maintain the concentration at up to 20 g / L. The term "spores" as used herein refer to reproductive structures produced by fungi. The spores are typically small, single-celled structures that can develop into new fungi under suitable conditions. In this regard, the spores from a designated species are either cultured on agar supplemented with a complex media, which could be for example Potato Dextrose in the concentration of 5 to 80 g / L, or one or more of maltbased complex medium in the concentration of 7.8 to 30 g / L with respect to a total concentration of the first composition, an organic nitrogen source such as soy protein or yeast extract in a concentration of 5 g / L with respect to a total concentration of the first composition, agar in a concentration of 10 to 20 g / L with respect to a total concentration of the first composition, and autoclaved organic carbon source solution in a concentration of 2 g / L with respect to a total concentration of the first composition and incubated for 1 to 4 weeks at a temperature between 20 and 42 °C with atmospheric gaseous exchange. Herein, the term "Tween solution" refers to a solution containing Tween, which is a type of surfactant or emulsifier. Specifically, the Tween is a non-ionic detergent composed of sorbitan esters and ethylene oxide, often used in microbiology and molecular biology. Advantageously, the Tween solution serves to create an environment conducive to the efficient collection and processing of spores. Advantageously, the Tween solution aids in preventing clumping and aggregation of the spores, facilitating their even dispersion in the solution. Following incubation, the harvested spores are meticulously processed: collected in a Tween solution, filtered, centrifuged, and washed before adjusting to a concentration of 1x10A6 and 5x10A8, typically 1x10A7 spores / ml (milliliter). The spore preparation is stored frozen for subsequent use in the inoculum creation process. In the subsequent steps of the method, the thawed spore preparation is introduced into shake flasks containing the base media composition, with the 40% organic carbon source solution added post-autoclaving to final concentration of 7.8 to 30 g / L, typically 20 g / L. Optionally, the incubation in a shaker incubator at controlled conditions facilitates the initiation of mycelium growth over a specified duration. The resulting medium, comprising the base media composition, the antifoam solution, and the introduced inoculum culture medium, forms the essential "first composition" for subsequent stages. This process ensures the homogenous integration of the inoculum culture medium into the larger mixture, providing an environment rich in essential nutrients for optimal mycelium development. The resulting first composition serves as the essential component for the mycelium biomass production process for further growth. Furthermore, the method comprises aerating the first composition at a pre-defined aeration rate, wherein the aeration rate is programmed to vary throughout the process. The term "aeration" refers to the introduction of air into a mixture or medium. The aeration (namely, aerating) plays an important role in providing oxygen to the growing mycelium, supporting its metabolic processes. The aeration process is conducted at a pre-defined rate, wherein the aeration rate is programmed to vary throughout the process. The pre-defined aeration rate or rates specify the volume of air introduced per volume of liquid per minute. Optionally, the pre-defined aeration rate or rates are in a range of 0.1 volume of air per volume of liquid per minute to 0.9 volume of air per volume of liquid per minute. The aforementioned range indicates the quantity of air provided relative to the volume of the liquid medium i.e., the fermentation broth or the first composition. Advantageously, the pre-defined aeration rate or rates are adjustable within the range of 0.1, 0.4, 0.6, or 0.8 volume of air per volume of liquid per minute up to 0.4, 0.6, 0.8 or 0.9 volume of air per volume of liquid per minute, allowing for optimization based on the specific requirements of the mycelium cultivation process. Moreover, the method comprises harvesting the mycelium biomass from the aerated first composition. In this regard, the mycelium in the form of large, globular masses is collected and the harvested mycelium biomass is further processed. During the harvesting, the mycelium biomass is removed and separated from the aerated first composition by gravitational separation. The harvesting is performed using mesh bags at a small scale or a belt sieve or similar in a larger scale, continuous process. The mycelium biomass may be free-floating or adhered to surfaces within a bioreactor system. Optionally, the method comprises a size reduction step where the masses of the mycelium biomass are broken apart into smaller chunks. Optionally, the method comprises washing the harvested mycelium biomass; providing heat treatment to the harvested mycelium biomass; packaging the harvested mycelium biomass; and freezing the packaged mycelium biomass at a temperature in a range of -20°C to -1°C. In this regard, the harvested mycelium is washed with water, preferably reverse osmosis water, to remove any residual medium, impurities, or unwanted substances. Beneficially, the washing ensures the purity and cleanliness of the harvested mycelium biomass. Optionally, the washing may involve several changes of water and agitation / compression of the mycelium biomass to facilitate the process of removing residual fermentation broth or the aerated first composition. Then the harvested mycelium biomass is subjected to the heat treatment process which serves the dual purpose of inactivating the fungi and reducing its RNA content to an acceptable level (2% according to WHO guidelines). The heat treatment also acts as a pasteurisation step and it takes place by immersing the harvested mycelium biomass in a water bath and holding it at a certain core temperature for a certain time, typically 60 to 70 °C for 5 to 30 mins, for example, 65°C for 15 minutes. In some iterations the method of the heat treatment may involve steam or another method of heating, or the RNA reduction may be achieved by an alternate method to heating, for example physical, chemical, or enzymatic methods. The mycelium is removed from the water bath and gravitationally drained of water and chilled. The mycelium is packaged, e.g., vacuum packed in food-grade plastic and labelled. The packaged mycelium may be stored frozen at -18°C or below before later processing into a food product in the downstream process. Optionally, the packaged mycelium biomass is frozen at a temperature in a range of -20°C, -19°C, -18°C, -17°C, -16°C, -15°C, -14°C, -13°C, -12°C, -11°C, -10°C, -9°C, -8°C, -7°C, -6°C, -5°C, -4°C, -3°C or -2°C, up to -18°C, -17°C, -16°C, -15°C, -14°C, -13°C, -12°C, -11°C, -10°C, -9°C, -8°C, -7°C, -6°C, -5°C, -4°C, -3°C, -2°C, or-1°C. Optionally, the method further comprises employing flavouring agents in the harvested mycelium biomass; employing natural fats in the harvested mycelium biomass; and employing flavour enhancers, herbs, spices, carbohydrates, and proteins. Herein, the hydrocolloids refer to substances that form a gel-like consistency when mixed with water. The plant starches, derived from sources such as corn or potatoes, can act as thickeners or stabilizers. The natural colours are derived from plant sources and are used to impart colour to the final product i.e., the mycelium biomass. Employing the aforementioned ingredients into the harvested mycelium biomass can contribute to texture, stability, and visual appeal. Moreover, the flavouring agents are added to the mycelium biomass to enhance its taste profile. The flavouring agents allows for customization, and various natural or synthetic flavours that can be employed to produce the mycelium biomass with specific sensory characteristics. Furthermore, the natural fats, such as plant-based oils, are employed to the mycelium biomass to enhance its mouthfeel, texture, and overall sensory experience wherein natural fats also contribute as a nutrition to the product. Additionally, the flavour enhancers can intensify taste, while herbs and spices contribute distinctive aromatic profiles. Optionally, the carbohydrates and the proteins provide additional nutritional value and texture to the final product. Optionally, by incorporating hydrocolloids, starches, colours, flavouring agents, natural fats, and a variety of other ingredients, the mycelium biomass can be transformed into a more-realistic meat-like texture. Optionally, the method further comprises, filling the harvested mycelium biomass into one or more molds; pressing the harvested mycelium biomass to provide a shape to the harvested mycelium biomass, wherein the pressing comprises compressing the harvested mycelium biomass so that internal three-dimensional hyphal structures are compressed into flatter structures along one plain to give a fibrous structure, mimicking animal muscle fibre, and aligning the mycelium fibre structures in a direction perpendicular to the direction of the pressing; and slicing the harvested mycelium biomass into one or more portions of the harvested mycelium biomass. Herein, the term "molds" refer to containers or shapes that the mycelium biomass is processed in. The mycelium biomass is filled into one or more molds and is subjected to a pressing process. The pressing process involves applying pressure to the mycelium biomass within the one or more molds to give it a specific shape. The term "compressing" as used herein refers to a process in which three-dimensional hyphal structures within the mycelium biomass are compacted into flatter structures, which together provide a fibrous texture to the mycelium biomass. As part of the pressing process, the compressed mycelium structures formed by the pressing are aligned. The alignment is in a perpendicular direction to the pressing. This alignment contributes to the overall structural integrity and characteristics of the harvested mycelium biomass. The pressed and aligned mycelium biomass is then sliced into one or more portions. The slicing involves cutting or dividing the mycelium biomass into smaller pieces or sections. The present disclosure also relates to the bioreactor system for producing mycelium biomass as described above. Various embodiments and variants disclosed above, with respect to the aforementioned method for producing mycelium biomass, apply mutatis mutandis to the bioreactor system for producing mycelium biomass. The term "bioreactor system" as used herein refers to a controlled environment or device designed for the cultivation of biological organisms, typically microorganisms or cells, under precisely regulated conditions. The bioreactor system provides an optimal setting for the growth and production of biological products such as proteins, enzymes, or fungi products, such as the mycelium biomass. The bioreactor system comprises a vessel configured to obtain the base media composition and the antifoam solution. Herein the "vesseP' refers to a container or tank designed to hold and manage liquids or substances. Moreover, the bioreactor system comprises the autoclave arrangement. The autoclave arrangement refers to an arrangement equipped with an autoclave for sterilizing the mixture of the base media composition and the antifoam solution under specific parameters, ensuring a sterile environment for mycelium growth. The term "control arrangement" as used herein refers to the software and / or hardware in the system that is operable to implement specific algorithms therein. Furthermore, the bioreactor system comprises the control arrangement which manages and regulates a second set of parameters, essential for the subsequent stages of mycelium production. Optionally, the control arrangement comprises a temperature control unit, a rotational speed control unit, a pH control unit, and a time control unit. Moreover, the control arrangement employs a processor configured to perform the above mentioned operations. It will be appreciated that optionally the processor includes, but is not limited to, a microprocessor, a microcontroller, a complex instruction set computing (CISC) microprocessor, a reduced instruction set computer (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, or any other type of processing circuit. Furthermore, the term "processor" may refer to one or more individual processors, processing devices and various elements associated with the control arrangement. Additionally, the one or more individual processors, processing devices and elements are arranged in various architectures for responding to and processing the instructions that drive the bioreactor system. Additionally, the bioreactor system comprises an "agitator1', referring to the mechanical device designed to stir or mix substances within a container. The agitator is utilized to thoroughly mix the inoculum culture medium with the existing mixture in the vessel. The objective is to achieve a uniform distribution of oxygen throughout the vessel for oxygenation of the inoculum and nutrient-rich mixture. The bioreactor system comprises an "aeration unit' which refers to a mechanical component designed to introduce air or a gas into a liquid (i.e., the first composition) to promote oxygenation and facilitate the growth of the mycelium biomass. The predefined aeration rate or rates ensure that the oxygen supply is controlled and optimized for the specific needs of the mycelium culture. The bioreactor system comprises the harvesting mechanism configured to collect the mycelium biomass from the aerated first composition. Herein "harvesting mechanism" refers to a component designed to gather or collect the mycelium biomass that has developed within the bioreactor. The successful integration of the harvesting mechanism into the bioreactor system ensures a controlled and systematic approach to the production of mycelium biomass. Once harvested, the mycelium biomass can be further processed final food product such as steaks. Optionally, the base media composition comprises a malt extract, an organic nitrogen source, an organic carbon source, one or more micronutrient sources, growth factors, and distilled water. Optionally, the control arrangement comprises a temperature control unit, a rotational speed control unit, a pH control unit, and a time control unit. Optionally, inoculum culture medium comprises a species, a malt extract in a concentration of 30 g / L with respect to a total concentration of the first composition, an organic nitrogen source such as a yeast extract or soy peptone in a concentration of 5 g / L with respect to a total concentration of the first composition, the preautoclaved organic carbon source solution in a concentration of 20 g / L with respect to a total concentration of the first composition. Optionally, the pre-defined aeration rate is in a range of 0.1 volume of air per volume of liquid per minute to 0.9 volume of air per volume of liquid per minute, wherein the aeration rate is programmed to vary throughout the fermentation. Optionally, the bioreactor system further comprises a washing unit configured to wash the harvested mycelium biomass; a heating arrangement configured to provide a heat treatment to the harvested mycelium biomass; a packaging unit configured to pack the harvested mycelium biomass; and a cooling unit configured to freeze the packaged mycelium biomass at a temperature in a range of-20°C to -1°C. In this regard, the washing unit may involve, spray nozzles or jets, distilled water or cleaning solution, reservoir, and so forth. Optionally, the heating arrangement could be electric heaters, steam coils, or another heat source. Optionally, the packaging unit may include equipment such as filling machines, sealing machines, and labeling machines, depending on the type of packaging used. Optionally, the cooling unit may include a fan or cold air or water. Optionally, the bioreactor system further comprises a filling unit configured to fill the harvested mycelium biomass into one or more molds; a pressing unit configured to apply pressure to the harvested mycelium biomass to provide a shape to the harvested mycelium biomass; and a slicing unit configured to slice the harvested mycelium biomass into one or more portions of the harvested mycelium biomass. In this regard, optionally, the filing unit could be a conveyor system, auger, or another mechanism designed to move the harvested mycelium biomass from the storage or harvesting area to the one or more molds. Optionally, the one or more molds into which the mycelium biomass is filled determines the final shape of the mycelium-based product. The bioreactor system regulates and coordinates the filling process, ensuring consistency and precision in filling the one or more molds. The bioreactor system is designed to apply pressure to the filled molds containing the mycelium biomass. This could be performed using one or more hydraulic presses, pneumatic presses, or another type of pressing system. The slicing unit is used for cutting or slicing the pressed mycelium biomass into individual portions. The slicing unit can include blades, cutting wires, or other cutting tools. EXPERIMENTAL PART The mycelium biomass is poured into a long log-shaped mold with a cross-section in the shape of a steak. The mold is perforated with holes which allow the release of excess moisture during compression. Due to the dewatering nature of the pressing process, the extent of pressing determines the final moisture content of the end-product, for example the mycelium mixture may be pressed to an extent that results in a final moisture content of 20-95%. This can be related to the texture and perceived tenderness of the steak product, where lower moisture content is associated with greater density and toughness, and higher moisture content is associated with lesser density and greater tenderness. The resulting block, or log of steak product is sliced perpendicular to its length to produce individual steaks with a realistic steak-like shape. The resulting steaks have a unique, vertical meat-like structure imparted by the pressing process, where the vertical direction of compression results in horizontal structures of compressed layers of mycelium within the block, which are then translated into vertical, fiber-like structures when individual steaks are sliced from the log and laid flat. The end product is uniquely similar to whole-cut meat because of the way the mycelium is grown. The mycelium is grown in cohesive format so that the interconnected hyphal structures are intact and form a 3D structure, later processed by pressing in a mold, so that the intact 3D hyphal structures are squashed into a more 2D shapes like strands that replicate muscle fibre, therefore re-creating the grain of a piece of beef or the strands or layers of whole-cut chicken. The product and method of producing thereof does not use binders, or other intensive processing steps such as extrusion, to create a texture that mimics muscle tissue. DETAILED DESCRIPTION OF THE DRAWINGS Referring to FIG. 1, illustrated is a flowchart of steps of a method for producing mycelium biomass in accordance with an embodiment of the present disclosure. At step 102, a base media composition and an antifoam solution are obtained. At step 104, a mixture of the base media composition and the antifoam solution under a first set of parameters is sterilized. At step 106, an autoclaved organic carbon source solution in the mixture is obtained. At step 108, a second set of parameters is controlled. At step 110, an inoculum culture medium is obtained. At step 112, the inoculum culture medium is mixed to form a first composition. At step 114, the first composition is aerated at a pre-defined aeration rate or rates. At step 116, the mycelium biomass is harvested from the aerated first composition. Referring to FIG. 2, illustrated is a bioreactor system 200 for producing mycelium biomass, in accordance with an embodiment of the present disclosure. The bioreactor system 200 comprises a vessel 202, an autoclave arrangement 204, a control arrangement 206, an agitator 208, an aeration unit 210, and a harvesting mechanism 212. The vessel 202 is configured to obtain a base media composition and an antifoam solution, the autoclave arrangement 204 sterilizes the mixture of the base media and antifoam solution under a first set of parameters and further the control arrangement 206 regulate a second set of parameters. The vessel 202 is also configured to obtain an autoclaved organic carbon source solution and an inoculum culture medium. Moreover, the bioreactor system 200 comprises the agitator 208 configured to mix the inoculum culture medium in the mixture to form a first composition and the first composition is aerated in the aeration unit 210 at a pre-defined aeration rate or rates. Furthermore, the aerated first composition is harvested as the mycelium biomass using the harvesting mechanism 212. Referring to FIGs. 3A, 3B, and 3C illustrated are exemplary illustrations of mycelium biomass, in accordance with an embodiment of the present disclosure. Herein, the mycelium biomass is in the form of a log of a steak product. In Figure 3A, a three-dimensional log of steak product with three distinct configurations is illustrated: left configuration (A), center configuration (B), and right configuration (C). The left configuration (A) represents the log of steak in its uncompressed state, featuring a random arrangement of the three-dimensional hyphal structures within the mycelium biomass. In the center configuration (B), the log of steak is compressed, resulting in horizontally aligned compressed hyphal structures. The right configuration (C) depicts the resulting steak product, wherein the log has been sliced perpendicular to its length, yielding individual steaks with a realistic, steak-like shape. This slicing process together with the pressing imparts a unique vertical fibrous structure to the steaks, similar to thegrain of a beef steak. The compression process initially creates horizontal layers of compressed mycelium biomass within the log (the centre configuration (B)), which, when translated through slicing, transform into vertical, fibre-like structures in each individual steak (right configuration (C)). Figure 3B presents three distinct configurations: left configuration (D), centre configuration (E), and right configuration (F), showcasing a log of steak product with a pale-coloured portion imitating a beef steak fat cap. In this depiction, various hues of the mycelium are employed to create a visual effect resembling the muscle-and-fat-cap composition of the beef steak. The paler mycelium portion (depicted as vertical stripes pattern) is strategically added, ensuring its placement on the top surface of the log. The left configuration represents the log of steak product with the pale-colored portion, simulating a beef steak fat cap, prior to the pressing process. The centre configuration illustrates the log after the pressing procedure, showcasing the impact of compression on the overall appearance. The right configuration displays an individual steak that has been sliced from the log, highlighting the continuation of the pale-coloured portion on the top surface, successfully emulating the characteristic fat cap of a beef steak. Figure 3C depicts two distinct slicing configurations of the log of steak product. The log of the product is subjected to slicing using sharp blades oriented perpendicular to its length. The left configuration (G) of the illustrates the log of the steak product in its intact form before the slicing procedure. The right configuration (H) showcases a single steak that has been precisely sliced from the log, emphasizing the outcome of the slicing process. The log may be uniformly sliced into the steaks, each with a thickness of, for example, 2.5 cm.

Claims

12 12251. A method for producing mycelium biomass, the method comprising:5 obtaining a base media composition;sterilizing a mixture of the base media composition and the antifoam solution under a first set of parameters;obtaining an autoclaved organic carbon source solution in the mixture;controlling a second set of parameters for10 obtaining an inoculum culture medium, wherein the inoculum culture medium comprises a solution of spores in concentration of lxlO6- 5xl08 spores / ml, mixing the inoculum culture medium in the mixture to form a first composition, and;aerating the first composition at a pre-defined aeration rate, wherein the aeration rate 15 is programmed to vary, wherein the pre-defined aeration rate is in a range of 0.1 - 0.9 volume of air per volume of liquid per minute; andharvesting the mycelium biomass from the aerated first composition,wherein the mycelium biomass during fermentation is in the form of a cohesive, nondispersed, solid but malleable structure, and wherein the mycelium biomass has an 20 interconnected hyphal structure.

2. A method according to claim 1, wherein the base media composition comprises a malt-based complex media, an organic nitrogen source, an organic carbon source, one or more micronutrient sources, growth factors, and water.

253. A method according to claim 1, wherein the first step comprises obtaining an antifoam solution.

4. A method according to claim 1, wherein the first set of parameters comprises a 30 first temperature in a range of 100°C to 150°C, a first period in a range of 15 minutes to 35 minutes, a first rotational speed in a range of 50 rotations per minute to 1000 rotations per minute.

5. A method according to claim 1, wherein the second set of parameters comprises 35 a second temperature in a range of 20°C to 42°C, a second rotational speed in a range of 50 rotations per minute to 800 rotations per minute which can be varied throughout the fermentation, a pH value in a range of 4.5 to 7, a second period in a range of 2 days to 8 days.12 12256. A method according to claim 1, wherein the inoculum culture medium comprises a fungal species, a malt-based complex media in a concentration of 7.8 to 30 g / L with respect to a total concentration of the first composition, an organic nitrogen source in5 a concentration of 0.78 to 6 g / L with respect to a total concentration of the first composition, the autoclaved organic carbon source solution in a concentration of 20 g / L with respect to a total concentration of the first composition.

7. A method according to claim 1, further comprising10 washing the harvested mycelium biomass;providing heat treatment to the harvested mycelium biomass;packaging the harvested mycelium biomass; andfreezing the packaged mycelium biomass at a temperature in a range of -20°C to -1°C.15 8. A method according to claim 1, further comprisingemploying flavouring agents in the harvested mycelium biomass;employing natural fats in the harvested mycelium biomass; andemploying flavour enhancers, herbs, spices, carbohydrates, and proteins.20 9. A method according to claim 1, further comprisingfilling the harvested mycelium biomass into one or more moulds;pressing the harvested mycelium biomass to provide a shape to the harvested mycelium biomass, wherein the pressing comprises squashing the interconnected structures within the harvested mycelium biomass into flatter structures and25 aligning said structures into a perpendicular direction of the pressing; and slicing the harvested mycelium biomass into one or more portions of the harvested mycelium biomass.

10. A bioreactor system when used to produce a mycelium biomass, the bioreactor 30 system comprising:a vessel configured to obtain a base media composition and an antifoam solution;an autoclave arrangement configured to sterilize a mixture of the base media composition and the antifoam solution under a first set of parameters;a control arrangement configured to regulate a second set of parameters;35 the vessel configured to obtain an autoclaved organic carbon source solution in the mixture;12 1225the vessel configured to obtain an inoculum culture medium, wherein the inoculum culture medium comprises a solution of spores in concentration of lxlO6 - 5xl08 spores / ml;an agitator configured to mix the inoculum culture medium in the mixture to form a 5 first composition;an aeration unit configured to aerate the first composition at a pre-defined aeration rate, wherein the aeration rate is programmed to vary throughout the fermentation process, wherein the pre-defined aeration rate is in a range of 0.1 - 0.9 volume of air per volume of liquid per minute; and10 a harvesting mechanism configured to collect the mycelium biomass from the aerated first composition,wherein the mycelium biomass is in the form of a cohesive, non-dispersed, solid but malleable structure during fermentation, and wherein the mycelium biomass has an interconnected hyphal structure.1511. A bioreactor system according to claim 10, wherein the control arrangement comprises a temperature control unit, a rotational speed control unit, a pH control unit, an aeration control unit, and a time control unit.20 12. A bioreactor system according to claim 10, further comprisinga washing unit configured to wash the harvested mycelium biomass;a heating arrangement configured to provide a heat treatment to the harvested mycelium biomass;a packaging unit configured to pack the harvested mycelium biomass; and25 a cooling unit configured to freeze the packaged mycelium biomass at a temperature in a range of -20°C to -1°C.

13. A bioreactor system according to claim 1, wherein the harvested mycelium biomass further comprises hydrocolloids, plant starches, natural colours, flavouring30 agents, natural fats, flavour enhancers, herbs, spices, carbohydrates, and proteins.

14. A bioreactor system according to claim 10, further comprisinga filling unit configured to fill the harvested mycelium biomass into one or more moulds;35 a pressing unit configured to apply pressure to the harvested mycelium biomass to provide a shape to the harvested mycelium biomass; anda slicing unit configured to slice the harvested mycelium biomass into one or more portions of the harvested mycelium biomass.

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