Basidiomycetes Fermentation of Spent Grain Mash Fractions
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Solution Overview
Problem
The challenge in beer production is the inefficient utilization of spent grain, which has a short microbiological shelf life and is typically used as animal feed or fertilizer, while existing methods for protein production from fungi do not fully leverage the nutritional value of grain-based substrates.
Innovation Solution
A method that fractionates the mash from the brewing process into a low solids content fraction for beer production and a high solids content fraction for fermentation with basidiomycetes, converting the latter into protein-rich fungal mycelium with high biological value and aromatic substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If spent grain is used as animal feed or fertilizer, then it can be disposed of effectively, but its nutritional value for human consumption is lost
Solution Approach 1:
The patent applies parameter changes by fermenting spent grain with basidiomycetes under controlled conditions (aerobic or anaerobic fermentation, specific temperature ranges, pH control) to transform the substrate into a high-protein product with enhanced nutritional parameters, converting it from animal feed quality to human consumption quality
Solution Approach 2:
Basidiomycetes serve as an intermediary organism that transforms spent grain into high-protein fungal biomass. The fungi act as a mediator between the low-value spent grain and high-value protein product, enabling the conversion through their metabolic processes and mycelium formation
2Quantity of substance
If basidiomycetes are used to ferment spent grain for protein production, then high biological value proteins are obtained, but the process complexity increases
Solution Approach 1:
The patent segments the brewing process by separating spent grain recovery from traditional disposal pathways and creating a distinct fermentation stage with basidiomycetes. This segmentation allows independent optimization of each process stage and simplifies the overall system by treating spent grain conversion as a separate, modular unit
Solution Approach 2:
Basidiomycetes are used to ferment spent grain in a self-sustaining manner where the fungi utilize the spent grain components themselves as substrate, requiring minimal external intervention. The system leverages the natural metabolic capabilities of the fungi to convert complex substrates into desirable products
3Loss of time
If spent grain is stored for extended periods, then it can be processed later, but its microbiological shelf life is limited to only a few days
Solution Approach 1:
The patent applies preliminary action by recovering and processing spent grain immediately after separation from the brewing process, before microbiological degradation can occur. The fresh spent grain is directly fed to basidiomycetes for fermentation, eliminating the need for extended storage and associated quality risks
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the ecological balance by utilizing spent grain more effectively, producing proteins with high biological value and aromatic compounds, and reducing gluten content, making the process more efficient and environmentally friendly.
Implementation Method 1
the second fraction is inoculated with a fungal inoculate of basidiomycetes, the inoculated fraction is fermented and a protein-containing fungal mycelium is formed
Data Source
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AI summary
A process for producing beer or another beverage and a protein-containing product based on grain as a feedstock, wherein: • a mash is produced from malted and/or unmalted grain, • the mash is fractionated into a first fraction with a low solids content and a second fraction with a high solids content, • the first fraction is used for the production of beer or another beverage, • the second fraction is inoculated with a fungal inoculate of basidiomycetes, • the inoculated fraction is fermented, and • a protein-containing fungal mycelium is formed.