Filamentous Fungal Biomats via Surface Fermentation Media

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Solution Overview

Problem

Current methods for filamentous mycelia production, such as solid-substrate fermentation (SSF) and submerged fermentation, face challenges including separation difficulties, low biomass concentration, inefficient conversion rates, high energy and water consumption, and environmental impact, with biomass characteristics limiting utility in food and animal feed applications.

Innovation Solution

A novel surface fermentation method using a tailored artificial media for filamentous fungi, which allows for high-density filamentous biomat production with long filaments, minimal waste, and controlled C:N ratios, eliminating the need for aeration and reducing environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If solid-substrate fermentation (SSF) is used for filamentous mycelia production, then fungal biomass can be produced, but separation of biomass from substrate is difficult and conversion rates are low

Engineering Contradiction:

Improveconversion rateVSAvoidseparation difficulty

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent extracts the fungal growth process from solid substrate and transfers it to liquid media, allowing biomass to grow freely suspended in liquid rather than being bound to solid particles. This extraction enables easy separation through centrifugation or filtration while maintaining high conversion rates of substrate to biomass.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the physical state parameter of the fermentation medium from solid to liquid, fundamentally altering the separation characteristics. Liquid media allows biomass to be freely suspended and easily separated, while the controlled liquid environment also optimizes nutrient delivery and conversion efficiency.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional fermentation methods are used, then biomass is produced, but energy and water consumption are high

Engineering Contradiction:

Improvebiomass production rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent replaces intensive mechanical aeration and agitation systems with a passive liquid-based growth system. The liquid media naturally facilitates nutrient and oxygen delivery to biomass without requiring high-energy mechanical inputs, dramatically reducing energy consumption while maintaining high productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If conventional fermentation methods are used, then biomass is produced, but waste generation is high and environmental impact increases

Engineering Contradiction:

Improvebiomass yieldVSAvoidwaste generation

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent recovers and reuses the liquid fermentation media after biomass harvest, extracting remaining nutrients and preventing their discharge as waste. The media can be sterilized and reused for subsequent fermentation batches, dramatically reducing waste generation while maintaining consistent biomass yields.

Inventive Principle:

Principle #34Discarding and recovering

4Reliability

If SSF is used for fermentation, then fungal growth occurs, but aeration is difficult and oxygen supply is insufficient

Engineering Contradiction:

Improveoxygen supplyVSAvoidaeration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses liquid hydraulics to deliver oxygen and nutrients to the biomass. Dissolved oxygen in the liquid media provides reliable oxygen supply without complex mechanical aeration systems, as oxygen transfer occurs naturally through the liquid phase and surface aeration.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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

The method achieves high production rates with minimal energy, water, and waste generation, producing biomats suitable for a variety of industrial applications, including food and animal feed, with enhanced filament length and density.

Implementation Method 1

A novel surface fermentation method using a tailored artificial media for filamentous fungi, which allows for high-density filamentous biomat production with long filaments

Methodology Applied

Scientific EffectSurface fermentation: Fermentation

Implementation Method 2

producing biomats suitable for a variety of industrial applications, including food and animal feed, with enhanced filament length and density

Methodology Applied

Scientific EffectNutrient absorption: Absorption (physical)

Data Source

PatentUS20260035655A1Filamentous fungal biomats, methods of their production and methods of their use

Publication Date: 2026.02.05 THE FYNDER GROUP INC

AI summary

A novel method of growing fungi is disclosed which uses an engineered artificial media and produces high density filamentous fungi biomats that can be harvested with a minimum of processing and from which fungal products such as antibiotics, proteins, and lipids can be isolated, the method resulting in lowered fungus cultivation costs for energy usage, oxygenation, water usage and waste stream production.