Spun fungal mycelial biomass fibers

Abstract

Spun fibers that include fungal biomass are disclosed, as are methods for making and using such spun fibers. In some embodiments, a fungal biomass-based fibrous material is formed by extruding a spun fiber starting mixture comprising the fungal biomass into a desired spatial configuration and subsequently treating the spun fiber starting mixture to form the fibrous material.

Description

[0001] SPUN FUNGAL MYCELIAL BIOMASS FIBERS

[0002] CROSS REFERENCE TO RELATED APPLICATION

[0003] This application claims the benefit of priority of U.S. Provisional Patent Application 63 / 682,962, filed 14 August 2024, the entirety of which is incorporated herein by reference.

[0004] FIELD

[0005] This disclosure relates generally to fungal mycelial biomass-based materials, and methods for the manufacture thereof, and particularly to methods of making fungal mycelial biomass-based materials by the spinning and / or extrusion of materials comprising fungal mycelial biomass.

[0006] BACKGROUND

[0007] The United Nations listed the world population as 7.5 billion in August 2017 and predicts that figure to grow to 8 billion in 2023 and to be 10 billion in 2056. In a related report, the Food and Agricultural Organization of the United Nations (FAO) estimates that if the global population reaches 9.1 billion by 2050, world food production will need to rise by 70% and to double in the developing world. That increase in food production will need to occur despite rising energy costs, decreasing underground aquifer resources, loss of farmland to urban sprawl, and increasingly severe weather due to climate change (e.g. increased temperatures, increased drought, increased flooding, etc.). This is a particular challenge for regions such as those located within continental Africa which, according to 2009 figures, already has inadequate protein intake and countries such as China, India, Pakistan, and Indonesia which are at risk of inadequate protein intake. In addition, the global demand for meat and dairy is forecasted for 2040 to increase by 60% for meat and 50% for dairy.

[0008] But not all protein sources are created equal. Animal -based foods (meat, eggs, dairy) provide “complete” proteins as they contain all of the essential amino acids; that is, methionine, leucine, isoleucine, phenylalanine, valine, threonine, histidine, tryptophan and lysine. Many plant-based foods, while containing some essential amino acids, generally lack the complete set. For example, the protein found in starchy roots lacks the essential amino acid lysine, which must then be obtained from another food in the diet. Beans and legumes contain high levels of lysine, but lack the essential amino acid methionine. Although it is possible to build a complete protein by pairing plant foods, ensuring a nutritionally balanced diet is much easier with complete proteins. One non-animal source of complete protein is edible filamentous fungi, such as Fusarium flavolapis, Fusarium venenatum, Neurospora crassa. and Pleurotus ostreatus. However, to date, post-production processing and formulation of fungal biomass into some types of meat analog products have failed to meet consumer expectations for achieving meat-like textures from fungal biomass. While some food production companies have made attempts to improve upon the innately fibrous nature of mycelium, for example by inducing ice-crystal formation to induce texture, a dehydration / rehydration process, and / or application of uniaxial pressure to align fibers and improve texture, these processes have been unsuccessful in replicating the texture of animal meat. Accordingly, there remains a need for improved processing techniques of fungal biomass into meat analog products.

[0009] SUMMARY

[0010] In various aspects, the present disclosure provides spun fiber compositions comprising fungal mycelial biomass. In some embodiments, spun fibers can be used to form food products that can be analogs of animal meat food products.

[0011] In a first aspect, the present disclosure provides a spun fiber comprising a fungal mycelial biomass. In some embodiments, the fungal mycelial biomass comprises at least about 80 wt% fungal mycelium. In some embodiments, the fungal mycelial biomass comprises particles, wherein at least about 50 dry wt% of the particles have a particle size of from about 10 pm to about 500 pm. In some embodiments, the fungal mycelial biomass was produced by a submerged fermentation method. In some embodiments, the fungal mycelial biomass was produced by a non-submerged fermentation method.

[0012] In some embodiments, the fungal mycelial biomass comprises biomass from a filamentous fungus selected from: a filamentous fungus belonging to a family selected from Mucoraceae, Ustilaginaceae, Hericiaceae, Polyporaceae, Grifolaceae, Lyophyllaceae, Strophariaceae, Lycoperdaceae, Agaricaceae, Pleurotaceae, Physalacriaceae, Ophiocordycipitaceae, Tuberaceae, Morchellaceae, Sparassidaceae, Nectriaceae, Bionectriaceae, or Cordycipitaceae; a filamentous fungus belonging to a species selected from Rhizopus oligosporus, Ustilago esculenta, Hericululm erinaceus, Polyporous squamosus, Grifola frondosa, Hypsizygus marmoreus, Hypsizygus ulmarius (elm oyster), Calocybe gambosa, Pholiota nameko, Calvatia gigantea, Agaricus bisporus, Stropharia rugosoannulata, Hypholoma lateritium, Pleurotus eryngii, Pleurotus ostreatus (pearl), Pleurotus ostreatus var. columbinus (Blue oyster), Tuber borchii, Morchella esculenta, Morchella conica, Morchella importuna, Sparassis crispa (cauliflower), Fusarium venenatum, Fusarium strain flavolapis (ATCC Accession Deposit No. PTA- 10698) or a derivative thereof, Disciotis venosa, Clonostachys rosea, Cordyceps militaris, Trametes versicolor, Ganoderma lucidum, Flammulina velutipes, Lentinula edodes, Pleurotus djamor, Pleurotus ostreatus, or Leucoagaricus spp.; a Fusarium species filamentous fungus; Fusarium venenatum filamentous fungus; or a Fusarium strain flavolapis (ATCC Accession Deposit No. PTA-10698).

[0013] In some embodiments, the spun fiber comprises from about 5 wt. % to about 35 wt. % fungal mycelial biomass.

[0014] In some embodiments, the spun fiber further comprises a gelling agent. In some embodiments, the gelling agent comprises a polysaccharide. In some embodiments, the gelling agent comprises a component selected from soluble fiber, cellulose, curdlan, starch, glycogen, sucrose, dextrin, hemicellulose, polydextrose, inulin, glucans, beta-glucan, pectin, psyllium husk mucilage, galactomannans, gums, beta-mannan, carob, fenugreek, gellan gum, guar gum, tara gum, methylcellulose, glucomannan gum, konjac gum, gum acacia, karaya gum, pullulan, tragacanth gum, arabinoxylan gum, xanthan gum, agar, alginate, carrageenan, chitin, chitosan, trehalose, and combinations thereof. In some embodiments, the spun fiber consists essentially of the fungal mycelial dough and gelling agent. In some embodiments, the spun fiber comprises from about 0.1 wt % to about 20 wt % gelling agent.

[0015] In some embodiments, the spun fiber further comprises an oil, a fat, or a combination of an oil and a fat. In some embodiments, the oil or fat is selected from acai oil, almond oil, avocado oil, blackcurrant seed oil, borage seed oil, canola oil, cashew oil, coconut oil, com oil, cottonseed oil, evening primrose oil, grapeseed oil, hazelnut oil, hemp oil, macadamia oil, olive oil, palm oil, peanut oil, pecan oil, pine seed oil, pistachio oil, pumpkin seed oil, safflower oil, sesame oil, soybean oil, sunflower oil, tea oil, walnut oil, coconut fat, palm fat, blubber, butter, chicken fat, clarified butter, cocoa butter, dripping, duck fat, fatback, lard, mango butter, margarine, schmaltz, shea butter, speck, suet, tail fat, tallow, vegetable shortening, or combinations thereof. In some embodiments, the spun fiber comprises from about 0.5 wt % to about 25 wt % of an oil / or a fat.

[0016] In some embodiments, the spun fiber has a width of about 5 pm to about 200 pm. In some embodiments, the spun fiber has a length of from about 1 mm to about 50 cm.

[0017] In some embodiments, the spun fiber is vegan.

[0018] In a second aspect, the present disclosure provides a food product, comprising one or more of the spun fibers disclosed herein. In some embodiments, the food product comprises an aggregation of the spun fiber. In some embodiments, the food product is a meat analog food product. In some embodiments, the meat analog food product is selected from a pork analog product, a beef analog product, a bison analog product, a lamb analog product, a poultry analog product, a shellfish analog product or a fish analog product.

[0019] In a third aspect, the present disclosure provides methods of producing a food material, comprising spinning a spun fiber starting mixture comprising fungal mycelial biomass to form a spun fiber. In some embodiments, the spinning is selected from immersed rotary jet spinning, electrospinning, blow spinning, solution blow spinning, wet spinning, jet spinning, or any combination thereof.

[0020] In some embodiments, the method further comprises collecting an aggregation of spun fibers. In some embodiments, the method further comprises modifying the moisture content of the aggregation of spun fibers. In some embodiments, the method further comprises modifying the density of the aggregation of spun fibers. In some embodiments, the modifying comprises mechanically processing the aggregation of spun fibers.

[0021] In some embodiments, the method further comprises combining an additional food component with the aggregation of spun fibers. In some embodiments, the additional food component is selected from flavorings, herbs, spices, flavor enhancers, oils, fats, fat replacers, preservatives, sweeteners, color additives, nutrients, emulsifiers, stabilizers, thickeners, pH control agents, acidulants, leavening agents, anti-caking agents, humectants, yeast nutrients, dough strengtheners, dough conditioners, firming agents, enzymes, gases, vegetables, fruits, plant proteins, meat products, and combinations thereof.

[0022] In some embodiments, the fungal mycelial biomass comprises biomass from a filamentous fungus belonging to a family selected from Mucoraceae, Ustilaginaceae, Hericiaceae, Polyporaceae, Grifolaceae, Lyophyllaceae, Strophariaceae, Lycoperdaceae, Agaricaceae, Pleurotaceae, Physalacriaceae, Ophiocordycipitaceae, Tuberaceae, Morchellaceae, Sparassidaceae, Nectriaceae, Bionectriaceae, or Cordycipitaceae . In some embodiments, the fungal mycelial biomass comprises biomass from a filamentous fungus belonging to a species selected from Rhizopus oligosporus, Ustilago esculenta, Hericululm erinaceus, Polyporous squamosus, Grifola frondosa, Hypsizygus marmoreus, Hypsizygus ulmarius (elm oyster), Calocybe gambosa, Pholiota nameko, Calvatia gigantea, Agaricus bisporus, Stropharia rugosoannulata, Hypholoma lateritium, Pleurotus eryngii, Pleurotus ostreatus (pearl), Pleurotus ostreatus var. columbinus (Blue oyster), Tuber borchii, Morchella esculenta, Morchella conica, Morchella importuna, Sparassis crispa (cauliflower), Fusarium venenatum, Fusarium strain flavolapis (ATCC Accession Deposit No. PTA- 10698) or a derivative thereof, Disciotis venosa, Clonostachys rosea, Cordyceps mililaris, Trametes versicolor, Ganoderma lucidum, Flammulina velutipes, Lentinula edodes, Pleurotus djamor, Pleurotus ostreatus, or Leucoagaricus spp. In some embodiments, the fungal mycelial biomass comprises biomass from a Fusarium species filamentous fungus. In some embodiments, the fungal mycelial biomass comprises a Fusarium venenatum filamentous fungus. In some embodiments, the fungal mycelial biomass comprises Fusarium strain flavolapis (ATCC Accession Deposit No. PTA-10698) or a derivative thereof.

[0023] In various aspects, the spun fiber comprises from about 5 wt. % to about 35 wt. % fungal mycelial biomass. In some embodiments, the spun fiber comprises a ratio of biomass to gelling agent (e.g., gellan powder) of about 8: 1. In some embodiments, the spun fiber comprises a ratio of biomass to gelling agent of about 10: 1. In some embodiments, the spun fiber comprises a ratio of biomass to gelling agent of about 12: 1 . In some embodiments, the spun fiber comprises a ratio of biomass to gelling agent of about 14:1.

[0024] In some embodiments, the spun fiber may further comprise a gelling agent, such as a polysaccharide. In some embodiments, the polysaccharide may be soluble fiber, cellulose, curdlan, starch, glycogen, sucrose, dextrin, hemicellulose, polydextrose, inulin, glucans, beta-glucan, pectin, psyllium husk mucilage, galactomannans, gums, beta-mannan, carob, fenugreek, gellan gum, guar gum, tara gum, methylcellulose, glucomannan gum, konjac gum, gum acacia, karaya gum, pullulan, tragacanth gum, arabinoxylan gum, xanthan gum, agar, alginate, carrageenan, chitin, chitosan, trehalose, or any combination thereof. In some embodiments, the spun fiber comprises about 0.1 wt % to about 20 wt % polysaccharide, or any subrange thereof.

[0025] In some embodiments, the spun fiber further comprises an oil and / or a fat. In some embodiments, an oil has a liquid consistency at room temperature. In some embodiments, a fat has a solid consistency at room temperature. In some embodiments, the oil and / or fat may be selected from acai oil, almond oil, avocado oil, blackcurrant seed oil, borage seed oil, canola oil, cashew oil, coconut oil, corn oil, cottonseed oil, evening primrose oil, grapeseed oil, hazelnut oil, hemp oil, macadamia oil, olive oil, palm oil, peanut oil, pecan oil, pine seed oil, pistachio oil, pumpkin seed oil, safflower oil, sesame oil, soybean oil, sunflower oil, tea oil, walnut oil, coconut fat, palm fat, blubber, butter, chicken fat, clarified butter, cocoa butter, dripping, duck fat, fatback, lard, mango butter, margarine, schmaltz, shea butter, speck, suet, tail fat, tallow, vegetable shortening, or combinations thereof.

[0026] In some embodiments, the spun fiber is vegan. In some embodiments, the spun fiber has a width of about 1 - about 2,000 pm, or any subrange thereof. In some embodiments, the fiber width is selected from about 1 - about 2,000 pm, about 1 - about 1,000 pm, about 1 - about 500 pm, about 1 - about 250 pm, about 5 - about 200 pm, about 10 - about 150 pm, and about 20 - about 100 pm. In some embodiments, the fiber width is about 20 - about 100 pm.

[0027] In another aspect, the present disclosure provides a food product comprising a spun fiber, the spun fiber comprising fungal mycelial biomass.

[0028] In some embodiments, the food product is a meat analog. In some embodiments, the meat analog is an analog of pork, beef, poultry, lamb, or fish, and can either be a whole meat analog or shredded meat analog. In some embodiments, the meat analog is a highly textured product.

[0029] A further aspect of the present disclosure provides a method of producing a food material. The method comprises spinning a spun fiber starting mixture that comprises fungal mycelial biomass to form a fiber from the spun fiber starting mixture. In some embodiments, the spun fiber starting mixture is an aqueous liquid dispersion of fungal mycelial biomass particles. In some embodiments, at least 50% of the fungal mycelial biomass particles are from about 1 pm to about 500 pm. In some embodiments, at least 50% of the fungal mycelial biomass particles are from about 10 pm to about 300 pm, or any subrange thereof.

[0030] In some embodiments, the spun fiber starting mixture comprises about 3 wt. % to about 20 wt. % fungal mycelial biomass solids, or any subrange thereof. In some embodiments, the spun fiber starting mixture may comprise about 6 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 8 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 10 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 12 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 14 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 16 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 18 wt.% fungal mycelial biomass solids.

[0031] In some embodiments, the fungal mycelial biomass is produced by a submerged fermentation method. In some embodiments, the fungal mycelial biomass is produced by a non-submerged fermentation method. In some embodiments, spun fibers are produced from a size-reduced, fermentation-derived fungal mycelial biomass in a form selected from a flour-like material produced by drying (e.g., spray-drying), and / or a dewatered fungal biomass (e.g, a dough or paste-like material). Size-reduction can occur via any one or more suitable means, for example mechanical means such as cutting, chopping, dicing, mincing, grinding, milling, blending, etc., or via sonication.

[0032] In some embodiments, the fungal mycelial biomass comprises biomass from a filamentous fungus belonging to a family selected from Mucoraceae, Ustilaginaceae, Hericiaceae, Polyporaceae, Grifolaceae, Lyophyllaceae, Strophariaceae, Lycoperdaceae, Agaricaceae, Pleurotaceae, Physalacriaceae, Ophiocordycipitaceae, Tuberaceae, Morchellaceae, Sparassidaceae, Nectriaceae, Bionectriaceae, or Cordycipitaceae . In some embodiments, the fungal mycelial biomass comprises biomass from a filamentous fungus belonging to a species selected from Rhizopus oligosporus, Ustilago esculenta, Hericululm erinaceus, Polyporous squamosus, Grifola frondosa, Hypsizygus marmoreus, Hypsizygus ulmarius (elm oyster), Calocybe gambosa, Pholiota nameko, Calvatia gigantea, Agaricus bisporus, Stropharia rugosoannulata, Hypholoma lateritium, Pleurotus eryngii, Pleurotus ostreatus (pearl), Pleurotus ostreatus var. columbinus (Blue oyster), Tuber borchii, Morchella esculenta, Morchella conica, Morchella importuna, Sparassis crispa (cauliflower), Fusarium venenatum, Fusarium strain flavolapis (ATCC Accession Deposit No. PTA- 10698) or a derivative thereof, Disciotis venosa, Clonostachys rosea, Cordyceps militaris, Trametes versicolor, Ganoderma lucidum, Flammulina velutipes, Lentinula edodes, Pleurotus djamor, Pleurotus ostreatus, or Leucoagaricus spp. In some embodiments, the fungal mycelial biomass comprises biomass from a Fusarium species filamentous fungus. In some embodiments, the fungal mycelial biomass comprises biomass from a Fusarium venenatum filamentous fungus. In some embodiments, the fungal mycelial biomass comprises biomass from a Fusarium strain flavolapis (ATCC Accession Deposit No. PTA-10698) or a derivative thereof.

[0033] In some embodiments, the spun fiber comprises at least about 3% fungal mycelial biomass, at least about 5 wt. % fungal mycelial biomass, at least about 10 wt. % fungal mycelial biomass, at least about 15 wt. % fungal mycelial biomass, at least about 20 wt. % fungal mycelial biomass, at least about 25 wt. % fungal mycelial biomass, at least about 30 wt. % fungal mycelial biomass, or at least about 35 wt. % fungal mycelial biomass. In some embodiments, the spun fiber comprises fungal mycelial biomass in a range from about 3 wt. % to about 75 wt. %, from about 5 wt. % to about 65 wt. %, from about 5 wt. % to about 50 wt. %, from about 5 wt. % to about 35 wt. % or any subrange of from about 3 wt. % to about 75 wt. %. In some embodiments, the spun fiber starting mixture further comprises a polysaccharide. In some embodiments, the polysaccharide may be a soluble fiber, cellulose, curdlan, starch, glycogen, sucrose, dextrin, hemicellulose, polydextrose, inulin, glucans, beta-glucan, pectin, psyllium husk mucilage, galactomannans, gums, beta-mannan, carob, fenugreek, gellan gum, guar gum, tara gum, methyl cellulose, glucomannan gum, konjac gum, gum acacia, karaya gum, pullulan, tragacanth gum, arabinoxylan gum, xanthan gum, agar, alginate, carrageenan, chitin, chitosan, trehalose, or any combination thereof.

[0034] In some embodiments, the spun fiber comprises about 0.1 wt % to about 20 wt % polysaccharide.

[0035] In some embodiments, the spun fiber starting mixture further comprises an oil and / or a fat. In some embodiments, the oil and / or fat may be selected from acai oil, almond oil, avocado oil, blackcurrant seed oil, borage seed oil, canola oil, cashew oil, coconut oil, com oil, cottonseed oil, evening primrose oil, grapeseed oil, hazelnut oil, hemp oil, macadamia oil, olive oil, palm oil, coconut fat, palm fat, peanut oil, pecan oil, pine seed oil, pistachio oil, pumpkin seed oil, safflower oil, sesame oil, soybean oil, sunflower oil, tea oil, walnut oil, blubber, butter, chicken fat, clarified butter, cocoa butter, dripping, duck fat, fatback, lard, mango butter, margarine, schmaltz, shea butter, speck, suet, tail fat, tallow, vegetable shortening, or combinations thereof.

[0036] In some embodiments, the method of producing a food material may further comprise aggregating a plurality of spun fibers. In some embodiments, the method may further comprise heating the spun fiber starting mixture to about 50 °C to about 95 °C.

[0037] In some embodiments, the step of spinning may be selected from immersed rotary jet spinning, electrospinning, blow spinning, solution blow spinning, wet spinning, jet spinning, or any combination thereof. Examples of jet spinning methods are described in U.S. Patent No. 11,174,571.

[0038] While specific embodiments and applications have been illustrated and described, the present disclosure is not limited to the precise configuration and components described herein. Various modifications, changes, and variations which will be apparent to those skilled in the art may be made in the arrangement, operation, and details of the methods and systems disclosed herein without departing from the spirit and scope of the overall disclosure.

[0039] The embodiments and configurations described herein are neither complete nor exhaustive. As will be appreciated, other embodiments are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 provides a schematic of spun fiber production from using a fiber spinning machine, according to embodiments of the present disclosure.

[0041] Figures 2A and 2B provide photographs of spun fibers produced using a fiber spinning machine, according to embodiments of the present disclosure.

[0042] DETAILED DESCRIPTION

[0043] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art. All patents, applications, published applications, and other publications to which reference is made herein are incorporated by reference in their entirety. If there is a plurality of definitions for a term herein, the definition provided in the Summary prevails unless otherwise stated. Definitions

[0044] As used herein, the following terms shall have the following meanings, unless the context expressly states, or clearly requires, otherwise.

[0045] The terms “about,” “approximately,” etc., when used in relation to numerical limitations or ranges, mean that the recited limitation or range may vary by up to 10%. By way of non-limiting example, “about 750” can mean as little as 675 or as much as 825, or any value therebetween. When used in relation to ratios or relationships between two or more numerical limitations or ranges, the terms “about,” “approximately,” etc. mean that each of the limitations or ranges may vary by up to 10%; by way of non-limiting example, a statement that two quantities are “approximately equal” can mean that a ratio between the two quantities is as little as 0.9: 1.1 or as much as L EON (or any value therebetween), and a statement that a four-way ratio is “about 5 :3 : 1 : 1” can mean that the first number in the ratio can be any value of at least 4.5 and no more than 5.5, the second number in the ratio can be any value of at least 2.7 and no more than 3.3, and so on.

[0046] The term “analog” or “analog food product” refers to a food product comprising edible fungi that bears an aesthetic, culinary, nutritional, and / or sensory equivalence or resemblance to an identified non-fungal food product. For example, the phrase “meat analog” can refer to a food product comprising edible fungi that bears an aesthetic, culinary, nutritional, and / or sensory equivalence or resemblance to a conventional meat product derived from an animal.

[0047] The term “aqueous” refers to any mixture or solution made of or containing water.

[0048] In that regard, an “aqueous” solution may contain water as the only solute or as one of two or more solutes. Similarly, an “aqueous” solution may contain water as the only solvent or as one of two or more solvents.

[0049] The term “biomass” refers to a mass of a living or formerly living organism. In some embodiments, this term specifically includes a mass of a living or formerly living filamentous fungus.

[0050] The term “colloid” refers to a mixture in which particles of one substance (the “dispersed phase”) are dispersed throughout a volume of a different substance (the “dispersion medium”); for example, the dispersed phase can comprise or consist of microscopic or macroscopic bubbles, particles, etc. Where the dispersed phase and the dispersion medium of a colloid are specifically identified herein, they are separated by a hyphen, with the dispersed phase identified first, e.g., a reference herein to an “oil-water colloid” refers to a colloid in which an oil is the dispersed phase and water is the dispersion medium.

[0051] The term “colloidal gel” refers to a colloid in which the dispersed phase is a liquid, and the dispersion medium is a solid. Examples of colloidal gels as that term is used herein include but are not limited to agar, hair gel, and opal.

[0052] The phrase “fungal mycelial biomass” refers to a biomass of filamentous fungus in which fungal mycelium makes up about 50 wt% to about 100 wt% of the biomass. In embodiments, fungal mycelium makes up at least about 50 wt%, at least about 55 wt%, at least about 60 wt%, at least about 65 wt%, at least about 70 wt%, at least about 75 wt%, at least about 80 wt%, at least about 85 wt%, at least about 90 wt%, at least about 95 wt%, at least about 96 wt%, at least about 97 wt%, at least about 98 wt%, at least about 99 wt%, or substantially all of the biomass. The remainder (i.e., the non-mycelial portion) of the mycelial biomass may contain other fungal tissues (conidia, fruiting bodies, etc.). “Mycelial biomass” specifically includes biomass produced by any fermentation method and thus encompasses biomass produced by submerged fermentation methods and non-submerged fermentation methods. In some embodiments, a mycelial biomass is produced by any one or more submerged fermentation methods known in the art, such as, for example, those described in U.S. Patent 7,635,492. More specifically, the phrase “cohesive mycelial biomass” refers to a mycelial biomass that is produced by a fermentation process other than a submerged fermentation process and that has sufficient tensile strength and structural integrity to be picked up and moved by hand without disintegrating or tearing. Cohesive mycelial biomasses can be produced by any one or more fungal fermentation methods in which the filamentous fungus grows in such a way as to form a mass of interwoven my celia, e.g., methods in which a fungal mycelium is grown in air or a controlled atmosphere out of a growth medium or feedstock e.g. , liquid surface fermentation, fermentation on the surface of a membrane or mesh scaffold, etc.). Suitable methods of producing a “cohesive mycelial biomass” are described in PCT Application Publication Nos. WO 2020 / 176758, WO 2020 / 154722, WO 2018 / 014004, and / or WO 2017 / 151684. Generally, mycelial biomasses recovered from submerged fermentation processes are paste-like substances with lower tensile strength and structural integrity and thus are not cohesive mycelial biomasses.

[0053] The term “inactivated” refers to a filamentous fungal biomass in which the fungal cells have been rendered nonviable, or enzymes capable of degrading or causing biochemical transformations within the biomass have been deactivated, or both. By extension, the term “inactivation” refers to any method or process by which a filamentous fungal biomass may be inactivated, such as, by way of non-limiting example, boiling, immersion in an organic liquid (e.g., an alcohol, peracetic acid, etc.), irradiation, pressure treatment, rinsing, size reduction, steaming, and temperature cycling. In some embodiments, an inactivated fungal mycelial biomass is biologically dead.

[0054] The phrase “liquid surface fermentation” refers to non-submerged fungal fermentation in which fungal mycelium is grown on the surface of a liquid fermentation media. A liquid surface fermentation can be a fermentation in which the fermentation medium is fully liquid or a fermentation in which the fermentation medium is a liquid medium that comprises a submerged solid substrate that releases nutrients into the liquid medium to support fungal fermentation. In both instances, fungal growth is on the surface of the liquid.

[0055] The phrase “non-submerged fermentation” refers to fungal fermentation that takes place primarily on the surface of a feedstock which can be solid or liquid. Examples of nonsubmerged fermentation include without limitation, liquid surface fermentation, solid state fermentation, fermentation on the surface of a membrane or mesh scaffold, etc.

[0056] The term “particle” refers to a small, discrete, localized object to which can be ascribed chemical or physical properties such as volume, density, and / or mass. “Particles,” as that term is used herein, may be microscopic or macroscopic; may be in the gas (e.g., air bubbles), liquid (e.g., droplets of the dispersed phase in an emulsion), or solid (e.g., granules of a powder) phase; and may take any of a variety of shapes (e.g., spheres, oblate spheroids, fibers, tubes, rods, etc.). Particles in the solid phase may be referred to herein as “particulates” or “particulate matter.” The phrase “solid state fermentation” refers to non-submerged fermentation in which fungal mycelium is grown on the surface of a solid substrate. In embodiments, a solid nutritive material (such as lignocellulosic material) can be inoculated with an aqueous inoculum of a fungal organism causing growth of the filamentous fungus throughout the solid substrate to form a fungal / substrate composite. Then, a high purity mycelial biomass can be grown on top of such a composite and can be separated from the composite as a cohesive mycelial biomass (also referred to as a panel, sheet or biomat). Examples of solid substrate surface fermentation are described in PCT Publication WO 2020 / 154722

[0057] The phrase “submerged fermentation” refers to fungal fermentation that takes place primarily submerged in a liquid medium. For example, submerged fermentation refers to fermentations wherein the microorganisms employed grow in a submerged state within fermentation media.

[0058] The present disclosure provides methods for producing spun fibers that contain biomass, such as fungal mycelial biomass, as well as food products containing the resulting spun fibers. According to various embodiments of the present disclosure, spun fibers containing fungal mycelial biomass are produced by a method comprising (1) adding one or more components to a fungal biomass comprising fungal mycelium, thereby generating a spun fiber starting mixture; (2) feeding the spun fiber starting mixture to a fiber spinning machine; and (3) generating centrifugal force through rotation of a compartment of the fiber spinning machine, thereby forming spun fibers containing fungal mycelial biomass through one or more orifices within the fiber spinning machine. In some embodiments, a spun fiber starting mixture is a flowable mixture. In some embodiments, a spun fiber that comprises fungal mycelial biomass may be included in a food product. In some embodiments, the food product may be a meat analog.

[0059] Spun Fiber Starting Mixture

[0060] The present disclosure provides a method for producing spun fibers comprising fungal mycelial biomass and having advantageous and beneficial properties. The present disclosure also provides methods for producing food products that comprise spun fibers containing fungal mycelial biomass. In some embodiments, fungal mycelial biomass is processed to produce a spun fiber starting mixture. This spun fiber starting mixture may then be fed to a fiber spinning machine and subjected to centrifugal and / or rotational forces to produce spun fibers containing fungal mycelial biomass.

[0061] Edible Filamentous Fungi Edible filamentous fungi, and particularly, fungal mycelial biomass from filamentous fungi, can be used as a nutrition source, such as for protein, either alone or incorporated into foodstuffs, such as the disclosed fungal food products. Described in some embodiments herein are solid fungal food products comprising spun fibers containing edible fungal mycelial biomass.

[0062] Filamentous fungi suitable for use in the disclosed methods, materials, and products are selected from the phyla or divisions Zygomycota, Glomermycota, Chytridiomycota, Basidiomycota or Ascomycota. The phylum (or division) Basidiomycota comprises, inter alia, the orders Agaricales, Russulales, Polyporales and Ustilaginales; the phylum Ascomycota comprises, inter alia, the orders Pezizales and Hypocreales; and the phylum Zygomycota comprises, inter alia, the order Mucorales. In some embodiments, the fungal mycelial biomass comprises biomass from a filamentous fungus belonging to a family selected from Mucoraceae, Ustilaginaceae, Hericiaceae, Polyporaceae, Grifolaceae, Lyophyllaceae, Strophariaceae, Ly coper daceae, Agaricaceae, Pleurotaceae, Physalacriaceae, Ophiocordycipitaceae, Tuberaceae, Morchellaceae, Sparassidaceae, Nectriaceae, Bionectriaceae, or Cordycipitaceae . In some embodiments, the particles of edible filamentous fungi provided by the present disclosure belong to an order selected from Ustilaginales, Russulales, Polyporales, Agaricales, Pezizales, Hypocreales, and Mucorales. In some embodiments, the filamentous fungi of the order Ustilaginales are selected from the family Ustilaginaceae . In some embodiments, the filamentous fungi of the order Russulales are selected from the family Hericiaceae . In some embodiments, the filamentous fungi of the order Polyporales are selected from the families Polyporaceae or Grifolaceae . In some embodiments, the filamentous fungi of the order Agaricales are selected from the families Lyophyllaceae, Strophariaceae, Ly coper daceae, Agaricaceae, Pleurotaceae, Physalacriaceae, or Omphalotaceae . In some embodiments, the filamentous fungi of the order Pezizales are selected from the families Tuberaceae or Morchellaceae . In some embodiments, the filamentous fungi of the order Mucorales are selected from the family Mucoraceae. In some embodiments, the filamentous fungi are from the genera Fusarium, Aspergillus, Trichoderma, Pleurotus, and / or Rhizopus.

[0063] Examples of the species of filamentous fungi suitable for use in the methods provided by the present disclosure include, without limitation, Rhizopus oligosporus, Ustilago esculenta, Hericululm erinaceus, Polyporous squamosus, Grifola fondrosa, Hypsizygus marmoreus, Hypsizygus ulmariuos (elm oyster), Calocybe gambosa, Pholiota nameko, Calvatia gigantea, Agaricus bisporus, Stropharia rugosoannulata, Hypholoma lateritium, Pleurotus eryngii, Pleurotus ostreatus (pearl), Pleurotus ostreatus var. columbinus (blue oyster), Tuber borchii. Morchella esculenla. Morchella conica. Morchella importuna, Sparassis crispa (cauliflower), Fusarium venenatum, Fusarium strain flavolapis (ATCC Accession Deposit No. PTA- 10698 or a derivative thereof), Disciotis venosa, Clonostachys rosea, Cordyceps mililaris, Trametes versicolor, Ganoderma lucidum (reishi), Flammulina velutipes, Lentinula edodes, and Ophiocordyceps sinensis. Additional examples include, without limitation, Trametes versicolor, Ceriporia lacerate, Pholiota gigantea, Leucoagaricus holosericeus, Pleurotus djamor, Pleurotus ostreatus, Calvatia fragilis, Handkea utriformis, and Rhizopus oligosporus.

[0064] In some embodiments, the filamentous fungus is a member of the genus Neurospora. In some embodiments, the filamentous fungus is Neurospora crassa. In some embodiments, the filamentous fungus is a member of the genus Pleurotus. In some embodiments, the filamentous fungus is Pleurotus ostreatus. In some embodiments, the filamentous fungus is a Fusarium species. In some embodiments, the filamentous fungus is Fusarium strain flavolapis (ATCC Accession Deposit No. PTA- 10698 or a derivative thereof), which may also be referred to herein as “F. flavolapis” or “Ff” In some embodiments, the filamentous fungus is Fusarium venenatum.

[0065] The amount of edible filamentous fungal biomass used in the disclosed methods can vary based on the desired protein content, texture, and / or flavor of the final solid and / or colloidal product.

[0066] Fungal Biomass Content

[0067] In some embodiments in which the biomass of the spun fiber starting mixture comprises fungal mycelial biomass, the particles of fungal biomass in the spun fiber starting mixture may be provided by any suitable method. By way of first non-limiting example, a whole or intact biomass or portion thereof (which may be inactivated and / or partially or completely dried, e.g., by lyophilization or convective drying) may be size-reduced to form discrete particles by any one or more suitable size-reduction techniques, such as, by way of non-limiting example, grinding (at either room or cryogenic temperature) and milling. In some embodiments, a process of reducing the size of a biomass or portion thereof may increase the relative temperature of the biomass. By way of second non-limiting example, “wet” deactivated sheets of biomass may be size-reduced (e.g., using a blade impeller) to a desired fiber length or particle size (e.g., a median fiber length or particle size of less than about 300 pm) and the “cut” sheets may be used in the formulation of the spun fiber starting mixture. By way of third non-limiting example, “wet” discrete filaments of mycelium or conidia may be produced by submerged fermentation and used to generate a spun fiber starting mixture for the generation of spun fibers. By way of fourth non-limiting example, discrete mycelial filaments or conidia may be spray-dried into a powder for use in formulation of a spun fiber starting mixture. In some embodiments, the spray dried particles are further size reduced by jet milling. In some embodiments, the particles of biomass in the spun fiber starting mixture may have a multi-modal particle size distribution. By way of fifth non-limiting example, the fungus may be fermented in a water-in-oil emulsion. By way of sixth non-limiting example, the fungus may be fermented as mycelial “shells” on the surface of stabilized air bubbles in a bulk reactor, z.e., by liquid-air interface fermentation, to produce hollow particles.

[0068] In some such embodiments, material properties of the spun fiber starting mixture and resulting materials can be improved by use of fine fungal particles (z.e., fungal particles having a relatively fine particle size). Particularly, the fungal particles may be characterized in that at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or substantially all of the particles of fungal biomass may have a particle size of from about 1 pm to about 500 pm, from about 10 pm to about 500 pm, from about 10 pm to about 400 pm, from about 10 pm to about 300 pm, from about 10 pm to about 200 pm, or any subrange between 1 pm and 500 pm.

[0069] Dx refers to the particle size distribution, wherein X denotes the percentage of particles that are below the indicated size. Thus, Dso means that 50% of the total particles are smaller than the indicated size and D90 means that 90% of the total particles are smaller than this size. In some embodiments, the D50 of the particles of fungal biomass may be no more than about 500 pm, no more than about 400 pm, no more than about 300 pm, no more than about 200 pm, no more than about 100 pm, no more than about 50 pm, no more than about 40 pm, no more than about 30 pm, or no more than about 20 pm; even more particularly, the D50 of the particles of fungal biomass may be about 17 pm to about 23 pm, about 18 pm to about 22 pm, about 19 pm to about 21 pm, and / or about 20 pm. In some embodiments, the D90 of the particles of fungal biomass may be about 30 pm to about 40 pm, about 31 pm to about 39 pm, about 32 pm to about 38 pm, about 33 pm to about 37 pm, about 34 pm to about 36 pm, and / or about 35 pm.

[0070] In some embodiments, the particle size distribution may be multimodal, i.e., bimodal, trimodal, or consisting of four or more modes. Properties and Production of Spun Fiber Starting Mixture

[0071] In the practice of embodiments of the methods according to the present disclosure, a spun fiber starting mixture, comprising fungal mycelial biomass and at least one additional component, is formed into a desired fiber by centrifugal and / or rotational forces. In many embodiments, this spun fiber starting mixture comprises particles of fungal mycelial biomass dispersed throughout a dispersion medium comprising at least one additional component. It is to be expressly understood, as further described throughout this disclosure, that such fungal particles may be derived from any filamentous fungal organism produced by any known fungal fermentation method (e.g., any one or more of the methods described in U.S. Patent 7,635,492 and / or PCT Application Publications WO9523843, WO2017151684, WO2018 / 014004, WO2019 / 099474, and / or WO2020 / 176758). In some embodiments, at least a portion of these filamentous fungal particles may be formed by sizereducing a fungal mycelial biomass (e.g., a biomat of a filamentous fungus produced by a surface fermentation process) by any suitable method, which may, by way of non-limiting example, comprise being processed (e.g., in a blender, food processor, jet mill, or similar size-reducing device), compressed (e.g., by moving jaws, rolls, gyratory cones, or similar compression device), impacted (e.g., by hammer, high-speed jet of material, rollers, or similar impact device), dried (e.g., by spray-drying, flash-drying, supercritical drying, freeze-drying, etc.), and combinations thereof, and the like. The size reduction process may be carried out in any suitable device for any suitable length of time, and the size reduction process may disrupt or destroy at least a portion of a cohesive interconnected or interwoven mycelial network of the fungal biomass. Additionally or alternatively, at least a portion of the filamentous fungal mycelial particles may be derived from a biomass that does not require size reduction, such as a fungal paste produced by dewatering fungal mycelial biomass produced by a submerged fermentation process or fungal mycelial particles produced by spray drying fungal biomass produced by, for example, a submerged fermentation process.

[0072] It is to be expressly understood that, in any embodiments, the spun fiber starting mixture may comprise filamentous fungal mycelial biomass of any one or more edible filamentous fungi and that such filamentous fungal mycelial biomass can be produced by any one or more fermentation methods referenced herein.

[0073] In some embodiments, a spun fiber starting mixture comprises fungal mycelial biomass and at least one additional component. In some embodiments, the fungal mycelial biomass in a spun fiber starting mixture comprises a fungal mycelial biomass dough or a liquid dispersion made from a fungal mycelial biomass dough. Fungal mycelial biomass dough may be produced using a variety of different methods, some of which are described herein. For example, fungal mycelial biomass dough may be produced by dewatering a mycelial biomass grown via submerged fermentation, such as a submerged slurry, and processing to a desired range of water content resulting in a submerged dough. A submerged slurry generally consists of a biomass-containing fluid (e.g., fermentation broth or water) and is produced by growing filamentous fungal biomass in fermentation medium using a submerged fermentation process. In some embodiments of producing a fungal biomass, the fermentation broth, itself, with the accumulated biomass, constitutes a submerged slurry. In some embodiments, a submerged slurry is produced by separating fungal biomass from a liquid fermentation broth, such as by filtration or decanting, washing the separated biomass, such as with water, to remove the fermentation medium, and resuspending the washed biomass in water to provide a submerged slurry. In some embodiments, a submerged slurry has a water content level of approximately 85% to 99%. Submerged doughs are biomasses with a generally dough-like consistency (i.e., they behave like a wet, solid mass). Submerged dough has a water content of approximately 60-85%.

[0074] In some embodiments, the fungal mycelial biomass in a spun fiber starting mixture comprises a fungal mycelial biomass flour. Fungal mycelial biomass flour may be produced, for example, by spray drying a liquid dispersion of fungal mycelial biomass (e.g., a submerged fungal mycelial dough or filamentous fungal biomat) or by grinding dried mycelial biomass into a flour.

[0075] Fungal Biomass Composition

[0076] In some embodiments, the fungal mycelial biomass in a spun fiber starting mixture comprises fungal mycelial biomass produced using a non-submerged fermentation method, such as liquid surface fermentation, membrane fermentation, or solid-state fermentation. A fungal mycelial biomass may be predominantly mycelial. Particularly, a fungal mycelial biomass dough or a fungal mycelial biomass flour may comprise more than 50% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 55% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 60% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 65% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 70% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 75% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 80% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 85% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 90% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 95% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 98% fungal mycelium. In some embodiments, a fungal mycelial dough or a fungal mycelial biomass flour comprises more than 99% fungal mycelium.

[0077] In some embodiments, fungal mycelial biomass comprises a submerged dough.

[0078] In some embodiments, a spun fiber starting mixture is formed by adding one or more components to a composition comprising fungal mycelial biomass.

[0079] In some embodiments, a deactivated fungal mycelial biomass may be washed with, for example, water. The fungal mycelial biomass may be analyzed to determine its percentage of solids. Once a percentage of solids is determined, the fungal mycelial biomass may be diluted using an aqueous solvent, such as water so that the percentage of fungal mycelial biomass solids in the spun fiber starting material is around 10%. In some embodiments, the percentage of solids of the diluted fungal mycelial biomass component may be I percent, 2 percent, 3 percent, 4 percent, 5 percent, 6 percent, 7 percent, 8 percent, 9 percent, 10 percent, I I percent, 12 percent, 13 percent, 14 percent, 15 percent, 16 percent, 17 percent, 18 percent, 19 percent, 20 percent, or more than 20 percent. In some embodiments, the percentage of solids of the diluted fungal mycelial biomass component can be from I percent to 20 percent or any subrange thereof, including from 3 percent to 20 percent. In some embodiments, a spun fiber starting mixture comprises diluted fungal mycelial dough. In some embodiments, a spun fiber starting mixture consists essentially of diluted fungal mycelial dough.

[0080] One or more additional components may be added to the spun fiber starting mixture in addition to fungal mycelial biomass. In some embodiments, the additional component is added prior to diluting the fungal mycelial biomass. In some embodiments, the additional component is added after diluting the fungal mycelial biomass. In some embodiments, the additional component is added simultaneously as the fungal mycelial biomass is being diluted.

[0081] Gelling Agent Compositions In some embodiments, the one or more additional components comprise a gelling agent. In some embodiments, the spun fiber starting mixture comprises a gelling agent and / or a non-gelling polysaccharide and / or a soluble fiber component. A gelling agent may be desirable in certain instances to provide the spun fiber starting mixture with certain rheological characteristics, e.g., a desired viscosity and / or yield stress. In some embodiments, a gelling agent is polysaccharide-based and / or protein-based. Gelatin and egg albumen are suitable protein-based gelling agents, for example. In some embodiments, a polysaccharide-based gelling agent comprises one or more of a soluble fiber, cellulose, curdlan, starch, glycogen, sucrose, dextrin, hemicellulose, polydextrose, inulin, glucans, beta-glucan, pectin, psyllium husk mucilage, galactomannans, gums, beta-mannan, carob, fenugreek, gellan gum, guar gum, tara gum, methylcellulose, glucomannan gum, konjac gum, gum acacia, karaya gum, pullulan, tragacanth gum, arabinoxylan gum, xanthan gum, agar, alginate, carrageenan, chitin, chitosan, trehalose, or any combination thereof. In some embodiments, a protein-based gelling agent comprises one or more of gelatin and / or an albumin, for example egg albumin. In some embodiments, a gelling agent comprises a gellan gum. Non-limiting examples of suitable gelling agents include one or more polymers with a molecular weight of at least about 80,000 daltons, which may, in some embodiments, include one or more polysaccharides, polypeptides, proteins, starches, block copolymers, poly electrolytes, vegetable gums, hydrocolloids (e.g., r-carrageenan, K-carrageenan, - carrageenan, agar, starch, modified starch, xanthan, guar gum, locust bean gum, gum arabic, acacia gum, gum karaya, gum tragacanth, alginate, pectin, methyl cellulose, hydroxypropyl methylcellulose, carboxymethyl cellulose, etc.), and combinations thereof.

[0082] In some embodiments, one or more gelling agents are mixed with diluted fungal mycelial biomass, thereby producing a spun fiber starting mixture.

[0083] Gelling Agent Content

[0084] In some embodiments comprising a gelling agent, the spun fiber starting mixture comprises a ratio of fungal mycelial biomass to gelling agent of from about 5 to 15 parts biomass to about 1 part gelling agent. In some embodiments, the spun fiber starting mixture comprises a ratio of biomass to gelling agent from about 5: 1 to about 15: 1 or any subrange of ratios in between 5: 1 and 15: 1 . In some embodiments, the spun fiber comprises a ratio of biomass to gelling agent of about 5: 1, 6: 1, 7: 1, 8: 1, 9:1,10: 1, 11 : 1, 12: 1, 13: 1, 14: 1, or 15: 1. In other embodiments, the spun fiber starting mixture can comprise gelling agent in a solids content of from about 0.1 % to about 12.0 %, or any subrange between 0.1 % and 12.0 %. Other Components for Addition to Spun Fiber Starting Mixture In some embodiments, the spun fiber starting mixture may also comprise other components in addition to fungal mycelial biomass and gelling agent. For example, the spun fiber starting mixture can also comprise from about 0.5 wt% to about 25 wt%, from about 0.5 wt% to about 15 wt%, from about 0.5 wt% to about 12 wt%, from about 0.5 wt% to about 10 wt%, or from about 0.5 wt% to about 5 wt% of an oil and / or a fat. As used herein, an oil is a liquid at room temperature. As used herein, a fat is a solid at room temperature. The method of producing a spun fiber starting mixture may comprise combining fungal mycelial biomass, optionally an aqueous solvent such as deionized water, and the oil and / or fat to form the spun fiber starting mixture. The combining step may comprise blending the fungal mycelial biomass, and optionally the solvent, with the oil and / or fat. The blending may comprise high-speed shearing. The high-speed shearing may comprise shearing the liquid phase, the filamentous fungal particles, and the oil and / or fat for at least about two minutes at a rotational speed of at least about 10,000 rpm. The oil and / or fat may comprise an oil selected from the group consisting of acai oil, almond oil, avocado oil, blackcurrant seed oil, borage seed oil, canola oil, cashew oil, coconut oil, corn oil, cottonseed oil, evening primrose oil, grapeseed oil, hazelnut oil, hemp oil, macadamia oil, olive oil, palm oil, peanut oil, pecan oil, pine seed oil, pistachio oil, pumpkin seed oil, safflower oil, sesame oil, soybean oil, sunflower oil, tea oil, walnut oil, and combinations thereof. The oil and / or fat may comprise a fat selected from the group consisting of blubber, butter, chicken fat, clarified butter, cocoa butter, dripping, duck fat, fatback, lard, mango butter, coconut fat, margarine, schmaltz, shea butter, speck, suet, tail fat, tallow, vegetable shortening, and combinations thereof.

[0085] Emulsifiers can be in spun fiber starting mixture, such as for example when oil and / or fat is used to stabilize the mixture. Incorporating the oil and / or fat into the spun fiber starting mixture can be difficult, because oils and / or fats are typically immiscible with water. Accordingly, in some embodiments, it may be useful to include an emulsifying agent when the spun fiber starting mixture includes an oil and / or a fat to facilitate the stability of the mixture. Emulsifiers suitable for use in the disclosed methods can include FDA-approved food additives. Suitable emulsifiers can be man-made or naturally occurring. For example, numerous hydrocolloids serve as thickening agents and support the structure, texture, flavor, and shelf life of various food products. They are often referred to simply as gums because of the food texture and consistency they create. Hydrocolloids include emulsifiers made from plants, animals, and aquatic sources. Plant-based hydrocolloids include locust bean gum, carrageenan, pectin, and starch, while animal-sourced varieties including chitosan made from crustacean shells. Hydrocolloids, like xanthan gum, can also come from microbial sources. In some embodiments, additional emulsifiers suitable for use in the disclosed methods include carboxymethylcellulose, cellulose, guar gum, lecithin, mono-and di-glycerides of fatty acids, polyglycerol esters of fatty acids, polyglycerol polyricinoleate, polysorbates, stearoyl lactylates, sorbitan esters, sucrose esters, sucroglycerides, and combinations thereof.

[0086] In some embodiments, the spun fiber starting mixture may comprise at least one salt of calcium or magnesium. The at least one salt of calcium or magnesium may be selected from the group consisting of calcium carbonate, calcium sorbate, calcium benzoate, calcium sulfite, calcium hydrogen sulfite, calcium formate, calcium acetate, calcium propionate, calcium ascorbate, calcium lactate, monocalcium citrate, dicalcium citrate, tricalcium citrate, monocalcium phosphate, dicalcium phosphate, tricalcium phosphate, calcium malate, calcium hydrogen malate, calcium tartrate, calcium fumarate, calcium glycerylphosphate, calcium disodium ethylene diamine tetraacetate, calcium lactobionate, calcium alginate, dicalcium diphosphate, calcium dihydrogen diphosphate, sodium calcium polyphosphate, calcium polyphosphate, calcium salts of fatty acids, calcium stearoyl-2- lactylate, calcium stearoyl fumarate, calcium chloride, calcium sulfate, calcium oxide, calcium ferrocyanide, dicalcium diphosphate, calcium sodium polyphosphate, calcium polyphosphate, calcium silicate, calcium aluminosilicate, calcium stearate, calcium gluconate, synthetic calcium aluminates, calcium diglutamate, calcium guanylate, calcium inosinate, calcium 5 ’-ribonucleotides, calcium iodate, calcium bromate, calcium peroxide, calcium cyclamate, calcium saccharate, magnesium lactate, monomagnesium phosphate, dimagnesium phosphate, magnesium citrate, magnesium salts of fatty acids, magnesium carbonate, magnesium bicarbonate, magnesium chloride, magnesium sulfate, magnesium oxide, magnesium silicate, magnesium trisilicate, magnesium stearate, magnesium gluconate, magnesium diglutamate, and combinations thereof.

[0087] In some embodiments, the spun fiber starting mixture may further comprise at least one of a flavoring agent, a taste modulator, and / or a flavor masker. Flavor maskers may be included to produce the Farish effect, whereby a flavor masker induces a chemical interaction in a subject that causes the reduction, or absence, of a taste. Flavor maskers are thus capable of masking undesirable flavors in food products, for example a plantmasker.

[0088] In some embodiments, the spun fiber starting mixture comprises one or more additional food components, such as flavorings, herbs, spices, flavor enhancers, fats, fat replacers, preservatives, sweeteners, color additives, nutrients, emulsifiers, stabilizers, thickeners, pH control agents, acidulants, leavening agents, anti-caking agents, humectants, yeast nutrients, dough strengtheners, dough conditioners, firming agents, enzymes, gases, vegetables, fruits, non-animal derived proteins such as plant proteins (for example, pea protein, soy protein, and textured vegetable protein), meat products, and combinations thereof. Typically, binders, flavors, spices, etc. are selected to meet the demands of a particular population. For example, milk and / or milk solids are not used to accommodate individuals with dairy allergies / sensitivities, wheat flour may not be used to accommodate those with gluten allergies / sensitivities, etc.

[0089] In some embodiments, the resultant spun fibers may be a food product, or may be suitable to be combined with one or more other food components to form a food product, that is analogous to a conventional or known food product comprising an animal-derived ingredient (e.g., a meat analog); the mycelial biomass may be provided in addition to or in lieu of the animal-derived ingredient.

[0090] In some embodiments, the resultant spun fibers may be a non-dairy composition, or more specifically a vegan composition (z.e., a composition that includes no animal-derived components). In some embodiments, the resultant spun fibers comprise a combination of fungal protein and plant protein.

[0091] In some embodiments, the resultant spun fibers may be non-animal and non-fungal compositions.

[0092] The spun fiber starting mixture may in some embodiments be a colloid. Particularly, the fungal mycelial biomass may be colloidally dispersed in the liquid fraction.

[0093] In some embodiments, spun fiber starting mixture comprises fungal mycelial biomass and one or more gelling agents. In some embodiments, spun fiber starting mixture comprises fungal mycelial biomass, one or more gelling agents, and at least one oil and / or fat component. In some embodiments, spun fiber starting mixture comprises fungal mycelial biomass, one or more gelling agents, a flavoring component, and at least one oil and / or fat component.

[0094] In some embodiments, spun fiber starting mixture consists essentially of fungal mycelial biomass and one or more gelling agents. In some embodiments, spun fiber starting mixture consists essentially of fungal mycelial biomass, one or more gelling agents, and at least one oil and / or fat component. In some embodiments, spun fiber starting mixture consists essentially of fungal mycelial biomass, one or more gelling agents, a flavoring component, and at least one oil and / or fat component. The basic and novel characteristics of a spun fiber starting mixture consisting essentially of fungal mycelial biomass and one or more gelling agents and optionally with at least one oil and / or fat component, is the ability of the mixture to form a mycelial-based spun fiber having the physical dimensions as described herein and suitable to produce meat analogs.

[0095] In some embodiments, the spun fiber content can be recycled and re-spun according to methods of the present disclosure. In some such embodiments, the spun fiber content can be combined with 0-99% of a fresh liquid fraction and fresh fungal biomass to form a spun fiber starting mixture capable of being formed into spun fibers. In some such embodiments, the spun fiber content can be processed (e.g., by regrinding or re-granulating the material) and re-spun. In some embodiments, the re-spun material may be re-compounded with 0- 99% of spun fiber starting mixture components, and either reformed directly into a desired shape or re-spun into a desired shape.

[0096] Properties and Use of Fiber Spinning Machine

[0097] In the practice of the methods of the present disclosure, a spun fiber starting mixture comprising one or more biomasses (e.g., fungal mycelial biomass) is spun and / or extruded, z.e., pushed through an orifice of a desired cross-section into a desired spatial configuration. By spinning and / or extruding the spun fiber starting mixture, spun fibers containing fungal biomass can be produced. Particularly, spinning fine fibers from fungal biomass can generate fibers that can be aggregated to form a realistic meat-like texture in a vegan food product.

[0098] In some embodiments, a spun fiber starting mixture may be formed into spun fibers by a fiber spinning machine capable of producing spun fibers that contain fungal mycelial biomass.

[0099] In the creation of spun fibers using a fiber spinning machine, an amount of spun fiber starting mixture provided by the present disclosure is provided to a bowl within the spinner head. The mixture is flowable and can be heated before introduction to the machine and / or while in the machine to facilitate fiber spinning. For example, in some embodiments heaters from within the fiber spinning machine can heat the mixture. As the spinner head rotates, the mixture moves out through holes in the spinner head. Particularly, centrifugal and / or rotational force is exerted upon the mixture, moving the mixture out of the spinner head. Strands of spun fiber then solidify in the air or other fluid medium and are caught in a collection bowl which surrounds the spinner head. As more spun fibers continue to accumulate in the collection bowl, a spun fiber collection tool may be used to gather the accumulated spun fibers. In one aspect, methods of producing a food material from spun fibers comprising fungal mycelial biomass are provided. In some embodiments, the methods comprise creating a plurality of spun fibers that comprise fungal mycelial biomass from a fiber spinning machine as provided herein, and forming the spun fibers into a food material. In some embodiments, the spun fiber starting mixture is an aqueous liquid dispersion of fungal mycelial biomass particles. In some embodiments, at least 50% of the fungal mycelial biomass particles are from about 1 pm to about 10 pm.

[0100] In some embodiments, the spun fiber starting mixture comprises about 3 wt. % to about 20 wt. % fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises from about 6 wt.%, 8 wt.%, 10 wt.%, or 12 wt.% up to about 14 wt.%, 16 wt.%, 18 wt.% or 20 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 8 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 10 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 12 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 14 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 16 wt.% fungal mycelial biomass solids. In some embodiments, the spun fiber starting mixture comprises about 18 wt.% fungal mycelial biomass solids. In some embodiments, the fungal mycelial biomass is in a format selected from dough, flour, and fungal mycelial biomass.

[0101] In some embodiments, orifices within the spinner head have a separation distance of 0.1 mm to 10 cm from other laterally spaced orifices. In some embodiments, by way of nonlimiting example, the orifices are manufactured to have a separation distance of about 0.1 mm to about 10 cm, or alternatively a separation distance in any range having a lower bound of any number of tenths of millimeters between 0.1 mm and 10 cm and an upper bound of any other number of tenths of millimeters between 0.1 mm and 10 cm.

[0102] In some embodiments, orifices within the spinner head have a diameter of 0.05 mm to 10 mm. In some embodiments, by way of non-limiting example, the orifices are manufactured to have a diameter in any range having a lower bound of any number of hundredths of millimeters between 0.05 mm and 10 mm and an upper bound of any other number of tenths of millimeters between 0.1 mm and 10 mm.

[0103] Generally, the diameter of the orifices within the spinner head can be set to produce spun fibers having a desired width. In some embodiments, the spun fiber has a width of about 1 - about 2,000 pm, or any subrange thereof. In some embodiments, the fiber width is selected from about 1 - about 2,000 m, about 1 - about 1,000 pm, about 1 - about 500 pm, about 1 - about 250 pm, about 5 - about 200 pm, about 10 - about 150 pm, and about 20 - about 100 pm. In some embodiments, the fiber width is about 20 - about 100 pm.

[0104] Figure 1 provides a schematic of spun fiber production from using a fiber spinning machine, according to embodiments of the present disclosure. In particular, the fiber spinning machine of Figure 1 illustrates a collection bowl 10, a motor 20, a spinner head 30 comprising a perforated spinning drum, and a heater 40.

[0105] The movement of the fiber spinning machine may generate centrifugal and / or rotational forces. These forces, in turn, may act as a force upon the spun fiber starting mixture 50, thereby drawing the mixture out and forming spun fibers 60. The rotation of the fiber spinning machine may be initiated and / or sustained by the motor 20 that is identified in Figure 3. In some embodiments, the motor 20 of a fiber spinning machine rotates at about 1,000 rpm to 5,000 rpm, or any subrange thereof. In some embodiments, the motor 20 rotates from about 500 rpm, about 1,000 rpm, about 1,500 rpm, about 2,000 rpm, or about 2,500 rpm, to about 3,000 rpm, about 3,500 rpm, about 4,000 rpm, about 4,500 rpm, or about 5,000 rpm. In some embodiments, the motor 20 of a fiber spinning machine rotates at a rate that is greater than 500 rpm, but less than 5,000 rpm. In some embodiments, the motor 20 of a fiber spinning machine rotates at from about 5,000 rpm to about 55,000 rpm, or any subrange thereof. In some embodiments, the motor 20 of a fiber spinning machine rotates at greater than 5,000 rpm, greater than 10,000 rpm, greater than 15,000 rpm, greater than 20,000 rpm, greater than 25,000 rpm, greater than 30,000 rpm, greater than 35,000 rpm, greater than 40,000 rpm, greater than 45,000 rpm, greater than 50,000 rpm, or at a rate that is greater than 5,000 rpm but less than 55,000 rpm.

[0106] In some embodiments, the application of heat to the spun fiber starting mixture 50 occurs when the spun fiber starting mixture 50 is within a fiber spinning machine. In some embodiments, the application of heat to the spun fiber starting mixture 50 occurs prior to when the spun fiber starting mixture 50 is fed to a fiber spinning machine. In some embodiments, the application of heat to the spun fiber starting mixture 50 occurs both when the spun fiber starting mixture 50 is within a fiber spinning machine as well as prior to when the spun fiber starting mixture 50 is fed to a fiber spinning machine. In some embodiments, heating the spun fiber starting mixture 50 activates one or more components within the spun fiber starting mixture 50, such as a gelling agent. In some embodiments, heating the spun fiber starting mixture 50 activates a gellan component of the spun fiber starting mixture. In some embodiments, a gellan component comprises gellan gum. In some embodiments, the spun fiber starting mixture 50 is heated to about 60 °C to about 100 °C, or any subrange thereof. In some embodiments, the spun fiber starting mixture 50 is heated to about 50 °C, about 60 °C, about 70 °C, about 75 °C, about 80 °C, about 85 °C, about 90 °C, about 95 °C, about 100 °C, about 105 °C, about 110 °C, about 120 °C, about 130 °C, about 140 °C, or greater than 140 °C.

[0107] In some embodiments, an alternative fiber spinning machine may be used to produce spun fibers in accordance with embodiments described herein. For example, a fiber spinning machine may comprise an immersion rotary jet-spinning machine. In some embodiments, a fiber spinning machine may provide for a form of spinning that is selected from immersed rotary jet spinning, electrospinning, blow spinning, solution blow spinning, wet spinning, jet spinning, or any combination thereof.

[0108] Fungal Mycelial Biomass Spun Fibers and Food Products

[0109] Figures 2A and 2B provide photographs of spun fibers produced using a fiber spinning machine, according to embodiments of the present disclosure. As seen in Figures 2A and 2B, spun fibers that have been generated are seen as collecting against a side of a collection bowl of the fiber spinning machine.

[0110] Spun Fiber Composition

[0111] As discussed above, spun fibers can be generated by processing a spun fiber starting mixture via a fiber spinning machine. As such, in some embodiments, the composition of spun fibers comprises a similar composition to its originating spun fiber starting mixture. In some embodiments, the composition of spun fibers comprises substantially the same composition as its originating spun fiber starting mixture. In some embodiments, moisture is lost during the spinning process such that the composition of the spun fibers comprises 0.01 wt% - 25 wt% less moisture than its originating spun fiber starting mixture. Description related to spun fiber starting mixture is provided above. In some embodiments, spun fibers comprise the same, or essentially, the same percentage of fungal mycelial biomass as its originating spun fiber starting mixture. In other embodiments, some water content in the spun fiber starting mixture can be lost during the process of forming a fiber resulting in a higher percentage content of the various other components in the mixture, such as the fungal mycelial biomass or gelling agent. In some embodiments, the spun fiber comprises at least about 3 wt. % fungal mycelial biomass, at least about 5 wt. % fungal mycelial biomass, at least about 10 wt. % fungal mycelial biomass, at least about 15 wt. % fungal mycelial biomass, at least about 20 wt. % fungal mycelial biomass, at least about 25 wt. % fungal mycelial biomass, at least about 30 wt. % fungal mycelial biomass, or at least about 35 wt. % fungal mycelial biomass. In some embodiments, the spun fiber comprises fungal mycelial biomass in a range from about 3 wt. % to about 75 wt. %, from about 5 wt. % to about 65 wt. %, from about 5 wt. % to about 50 wt. %, from about 5 wt. % to about 35 wt. % or any subrange of from about 3 wt. % to about 75 wt. %.

[0112] As discussed above, embodiments of a spun fiber starting mixture comprise one or more gelling agents. Spun fibers that are formed using some of these embodiments also comprise one or more gelling agents. In some embodiments, some water content in the spun fiber starting mixture can be lost during the process of forming a fiber resulting in a higher percentage content of the various other components in the mixture, such as the fungal mycelial biomass or gelling agent. In some embodiments, the spun fiber comprises at least about 0.1 wt. % gelling agent, at least about 0.5 wt. % gelling agent, at least about 1 wt. % gelling agent, at least about 2 wt. % gelling agent, at least about 3 wt. % gelling agent, at least about 4 wt. % gelling agent, at least about 5 wt. % gelling agent, at least about 10 wt. % gelling agent, or at least about 15 wt. % gelling agent. In embodiments, the spun fiber comprises gelling agent in a range from about 0.1 wt. % to about 20 wt. %, from about 0.1 wt. % to about 15 wt. %, from about 0.5 wt. % to about 10 wt. %, from about 1 wt. % to about 10 wt. % or any subrange of from about 0.1 wt. % to about 20 wt. %.

[0113] As discussed above, embodiments of a spun fiber starting mixture comprise an oil and / or fat component. Spun fibers that are formed using some of these embodiments also comprise an oil and / or fat component.

[0114] As discussed above, embodiments of a spun fiber starting mixture comprise a flavoring component. Spun fibers that are formed using some of these embodiments also comprise a flavoring component.

[0115] In some embodiments, spun fibers comprise fungal mycelial biomass and one or more gelling agents. In some embodiments, spun fibers comprise fungal mycelial biomass, one or more gelling agents, and at least one oil and / or fat component. In some embodiments, spun fibers comprise fungal mycelial biomass (e.g., fungal mycelial dough or flour), one or more gelling agents, a flavoring component, and at least one oil and / or fat component.

[0116] In some embodiments, the spun fiber has a width as described herein. In some embodiments, the length of a spun fiber is about 1 mm to about 50 cm. In some embodiments, the fiber length of a spun fiber is about 5 mm to about 20 cm. In some embodiments, the fiber length of a spun fiber is about 1 cm to about 10 cm. In some embodiments, the fiber length of a spun fiber is about 2 cm to about 5 cm. In some embodiments, the fiber length of a spun fiber is about 2 cm to about 4 cm. In some embodiments, the fiber length of a spun fiber is about 50 pm to about 5 cm, or any subrange thereof.

[0117] In some embodiments, the spun fiber is vegan.

[0118] Once spun fibers have been generated, they can be aggregated to form food products, such as food products that are meat analogs. In some embodiments, the meat analog is an analog of pork, beef, poultry, or fish, and can either be a whole meat analog or shredded meat analog. These processes are discussed further below.

[0119] Gathering and Processing Spun Fibers

[0120] In some embodiments, the spun fiber starting mixture may generate spun fibers at ambient and / or room temperature (“cold” extrusion), or above ambient and / or room temperature (“hot” or “warm” extrusion).

[0121] In some embodiments, forming spun fibers from a spun fiber starting mixture begins by heating the spun fiber starting mixture to an appropriate temperature and feeding the mixture into a reservoir of a fiber spinning machine to form fibers that are collected in a collection bowl. Once the spun fiber starting mixture is converted to spun fibers, an accumulation of spun fibers can be collected, e.g., into an aggregation of spun fibers. The collected spun fibers of fungal mycelial biomass can then be further processed into food products. For example, the moisture content of the collected fibers can be adjusted to a desired level such as by drying or adding moisture to the collected fibers. Alternatively or in addition, one or more additional food components, as described above, of the final product can be added to the collected fibers. Specifically, such components can include an oil and / or a fat and / or a flavoring to simulate an animal-based meat product.

[0122] Collected fibers can also be mechanically processed to more closely simulate the conventional meat product of which it is an analog. For example, collected fibers can be compressed or compacted to form more whole meat types of products such as steaks. Alternatively, collected fibers can be pulled apart to simulate pulled pork or pulled chicken types of products. Further, collected fibers can be formed into pieces that are of an appropriate density to simulate softer meat products such as some fish or shellfish. The collected fibers can be stretched, heat-treated, and / or cold-worked to straighten and / or elongate the material and / or provide a finished biomass-based material, such as a food product, with one or more desirable mechanical properties. For example, collected fibers can be formed into an appropriate texture for a given product and then cut into portion sizes consistent with conventional meat production practices. During processing of collected fibers, one or more additional food components can be added or combined with the aggregation of spun fibers, such as flavorings, herbs, spices, flavor enhancers, oils, fats, fat replacers, preservatives, sweeteners, color additives, nutrients, emulsifiers, stabilizers, thickeners, pH control agents, acidulants, leavening agents, anti-caking agents, humectants, yeast nutrients, dough strengtheners, dough conditioners, firming agents, enzymes, gases, vegetables, fruits, non-animal derived proteins such as plant proteins (for example, pea protein, soy protein, and textured vegetable protein), meat products, and combinations thereof.

[0123] In some embodiments, the food product is a meat analog. In some embodiments, the meat analog is an analog of pork, beef, bison, lamb, poultry (e.g., chicken, turkey, goose, duck, etc.), shellfish, or fish, and can either be a whole meat analog or shredded meat analog.

[0124] Embodiments of the present disclosure are further described by way of the following illustrative and non-limiting Examples.

[0125] Example 1:

[0126] Spun Fiber Production Procedure

[0127] Spun fibers of a fungal mycelial biomass-containing material were formed using a spinning fiber machine. In some embodiments, another electrospinning machine may be used.

[0128] Fusarium strain flavolapis (ATCC Accession Deposit No. PTA- 10698) biomass was grown via a stirred-tank submerged fermentation process followed by harvesting, washing, and inactivation of the fungal biomass to produce submerged fungal mycelial dough. The fungal mycelial dough was washed with a mixture having a ratio of ImL fermenter broth to ImL hot deionized (DI) water. A percentage of solids was assessed for the obtained submerged fungal mycelial dough.

[0129] The amount of solids within the fungal mycelial dough was adjusted by dilution with DI water. The diluted mixture was mixed thoroughly. In particular, the percentage of solids was adjusted until the diluted fungal mycelial dough contained 10% solids, thereby generating a 10% fungal mycelial dough mixture.

[0130] Thirty grams of the 10% fungal mycelial dough mixture was placed into a 50 mL falcon tube. Gellan powder was added to the 10% moisture fungal mycelial dough mixture at an amount equivalent to 1% of the mass of the fungal mycelial dough mixture. The gellan powder was a polysaccharide and a soluble fiber. The gellan powder was thoroughly mixed into the fungal mycelial dough mixture, thereby generating a gellan fungal mycelial dough mixture. Additionally, a fiber spinning machine (Vevor Model No. MHTJJPZY01, Sanven Corporation, Rancho Cucamonga, CA, USA) was turned on with the heat adjustment knob at the lowest setting. The machine was run for at least two minutes. The rotating bowl was heated up to about 60° C after ten minutes.

[0131] The gellan fungal mycelial dough mixture was heated in a container in a microwave over 20 second intervals. Between each interval, the gellan fungal mycelial dough mixture was stirred. Once the mixture began to boil in the microwave, the container was removed, the contents were stirred, and the contents were poured into the heated rotating bowl of the fiber spinning machine.

[0132] The fiber spinning machine then proceeded to generate spun fibers from the heated gellan fungal mycelial dough mixture. Particularly, spun fibers were produced using a dry spinning process of the fiber spinning machine.

[0133] The foregoing discussion has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features are grouped together in one or more embodiments for the purpose of streamlining the disclosure. The features of the embodiments may be combined in alternate embodiments other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claims require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment.

[0134] Moreover, though the present disclosure has included description of one or more embodiments and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable, and / or equivalent structures, functions, ranges, or steps to those claimed, regardless of whether such alternate, interchangeable, and / or equivalent structures, functions, ranges, or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

Claims

CLAIMS1. A spun fiber comprising a fungal mycelial biomass.

2. The spun fiber of claim 1, wherein the fungal mycelial biomass comprises at least about 80 wt% fungal mycelium.

3. The spun fiber of claim 1 or claim 2, wherein the fungal mycelial biomass comprises particles, wherein at least about 50 dry wt% of the particles have a particle size of from about 10 pm to about 500 pm.

4. The spun fiber of any one of claims 1-3, wherein the fungal mycelial biomass was produced by a submerged fermentation method.

5. The spun fiber of any one of claims 1-3, wherein the fungal mycelial biomass was produced by a non-submerged fermentation method.

6. The spun fiber of any one of claims 1-5, wherein the fungal mycelial biomass comprises biomass from a filamentous fungus selected from: a. a filamentous fungus belonging to a family selected from Mucoraceae, Ustilaginaceae, Hericiaceae, Polyporaceae, Grifolaceae, Lyophyllaceae, Strophariaceae, Lycoperdaceae, Agaricaceae, Pleurotaceae, Physalacriaceae, Ophiocordycipitaceae, Tuberaceae, Morchellaceae, Sparassidaceae, Nectriaceae, Bionectriaceae, or Cordycipitaceae; b. a filamentous fungus belonging to a species selected from Rhizopus oligosporus, Ustilago esculenta, Hericululm erinaceus, Polyporous squamosus, Grifola frondosa, Hypsizygus marmoreus, Hypsizygus ulmarius (elm oyster), Calocybe gambosa, Pholiota nameko, Calvatia gigantea, Agaricus bisporus, Stropharia rugosoannulata, Hypholoma lateritium, Pleurotus eryngii, Pleurotus ostreatus (pearl), Pleurotus ostreatus var. columbinus (Blue oyster), Tuber borchii, Morchella esculenta, Morchella conica, Morchella importuna, Sparassis crispa (cauliflower), Fusarium venenatum, Fusarium strain flavolapis (ATCC Accession Deposit No. PTA- 10698) or a derivative thereof, Disciotis venosa, Clonostachys rosea, Cordyceps militaris, Trametes versicolor, Ganoderma lucidum, Flammulina velutipes, Lentinula edodes, Pleurotus djamor, Pleurotus ostreatus, or Leucoagaricus spp.; c. a Fusarium species filamentous fungus; d. a Fusarium venenatum filamentous fungus; or e. a Fusarium strain flavolapis (ATCC Accession Deposit No. PTA-10698).

7. The spun fiber of any one of claims 1-6, wherein the spun fiber comprises from about 5 wt. % to about 35 wt. % fungal mycelial biomass.

8. The spun fiber of any one of claims 1-7, wherein the spun fiber further comprises a gelling agent.

9. The spun fiber of claim 8, wherein the gelling agent comprises a polysaccharide.

10. The spun fiber of claim 8 or claim 9, wherein the gelling agent comprises a component selected from soluble fiber, cellulose, curdlan, starch, glycogen, sucrose, dextrin, hemicellulose, polydextrose, inulin, glucans, beta-glucan, pectin, psyllium husk mucilage, galactomannans, gums, beta-mannan, carob, fenugreek, gellan gum, guar gum, tara gum, methylcellulose, glucomannan gum, konjac gum, gum acacia, karaya gum, pullulan, tragacanth gum, arabinoxylan gum, xanthan gum, agar, alginate, carrageenan, chitin, chitosan, trehalose, and combinations thereof.

11. The spun fiber of any one of claims 8-10, wherein the spun fiber consists essentially of the fungal mycelial dough and gelling agent.

12. The spun fiber of any one of claims 8-11, wherein the spun fiber comprises from about 0.1 wt % to about 20 wt % gelling agent.

13. The spun fiber of any one of claims 1-12, wherein the spun fiber further comprises an oil, a fat, or a combination of an oil and a fat.

14. The spun fiber of claim 13, wherein the oil or fat is selected from acai oil, almond oil, avocado oil, blackcurrant seed oil, borage seed oil, canola oil, cashew oil, coconut oil, corn oil, cottonseed oil, evening primrose oil, grapeseed oil, hazelnut oil, hemp oil, macadamia oil, olive oil, palm oil, peanut oil, pecan oil, pine seed oil, pistachio oil, pumpkin seed oil, safflower oil, sesame oil, soybean oil, sunflower oil, tea oil, walnut oil, coconut fat, palm fat, blubber, butter, chicken fat, clarified butter, cocoa butter, dripping, duck fat, fatback, lard, mango butter, margarine, schmaltz, shea butter, speck, suet, tail fat, tallow, vegetable shortening, or combinations thereof.

15. The spun fiber of claim 13 or claim 14, wherein the spun fiber comprises from about 0.5 wt % to about 25 wt % of an oil and / or a fat.

16. The spun fiber of any one of claims 1-15, wherein the spun fiber has a width of from about 5 pm to about 200 pm.

17. The spun fiber of any one of claims 1-16, wherein the spun fiber has a length of from about 1 mm to about 50 cm.

18. The spun fiber of any one of claims 1-17, wherein the spun fiber is vegan.

19. A food product, comprising a spun fiber of one of claims 1-18.

20. The food product of claim 19, wherein the food product comprises an aggregation of the spun fiber.

21. The food product of claim 19 or claim 20, wherein the food product is a meat analog food product.

22. The food product of claim 20, wherein the meat analog food product is selected from a pork analog product, a beef analog product, a bison analog product, a lamb analog product, a poultry analog product, a shellfish analog product or a fish analog product.

23. A method of producing a food material, comprising spinning a spun fiber starting mixture comprising fungal mycelial biomass to form a spun fiber.

24. The method of claim 23, wherein the spinning is selected from immersed rotary jet spinning, electrospinning, blow spinning, solution blow spinning, wet spinning, jet spinning, or any combination thereof.

25. The method of claim 23 or claim 24, further comprising collecting an aggregation of spun fibers.

26. The method of claim 25, further comprising modifying the moisture content of the aggregation of spun fibers.

27. The method of claim 25 or claim 26, further comprising modifying the density of the aggregation of spun fibers.

28. The method of claim 27, wherein the modifying comprises mechanically processing the aggregation of spun fibers.

29. The method of any one of claims 25-28, further comprising combining an additional food component with the aggregation of spun fibers.

30. The method of claim 29, wherein the additional food component is selected from flavorings, herbs, spices, flavor enhancers, oils, fats, fat replacers, preservatives, sweeteners, color additives, nutrients, emulsifiers, stabilizers, thickeners, pH control agents, acidulants, leavening agents, anti-caking agents, humectants, yeast nutrients, dough strengtheners, dough conditioners, firming agents, enzymes, gases, vegetables, fruits, plant proteins, meat products, and combinations thereof.

Images