Mycelial Biomass Fermentation for Scalable High-Protein Food Products
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Solution Overview
Problem
Current methods for producing fungal mycoprotein lack scalability, efficiency, and cost-effectiveness, and do not provide a clean-label, high-nutritional-value alternative to animal protein with desirable texture and fiber content.
Innovation Solution
A process involving the cultivation of filamentous fungi like Rhizopus oligosporus in a solid medium, followed by fermentation, filtration, rinsing, and inactivation, results in mycelial biomass with high protein and fiber content, which is then pressed and combined with minimal additives to create a food product resembling animal meat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional liquid culture or solid-state culture methods are used to produce mycoprotein, then fungal biomass can be obtained, but the production process lacks scalability, efficiency, and cost-effectiveness
Solution Approach 1:
The production process is segmented into distinct stages: inoculum preparation, fermentation, filtration, rinsing, and inactivation. Each stage is optimized independently, allowing for scalable implementation while maintaining process simplicity. The segmentation enables parallel processing and facilitates quality control at each step.
Solution Approach 2:
The patent optimizes critical process parameters including fermentation temperature (25-35°C), pH (5.0-6.0), aeration rate (0.5-2.0 vvm), and agitation speed (200-600 rpm) to maximize mycelial biomass production. These parameter changes enable high productivity while maintaining ease of manufacture through standardized control protocols.
2Shape
If mushroom production methods are used, then fungal biomass with cohesive structure can be obtained, but cultivation cycles are long and final sizes are limited
Solution Approach 1:
A pre-inoculum is prepared in advance by culturing fungal spores on solid medium for 3-7 days to develop robust mycelial mats. This preliminary action ensures that the main fermentation process starts with highly active inoculum, accelerating biomass production and reducing overall cultivation time while maintaining structural coherence.
Solution Approach 2:
The fermentation process operates continuously with constant aeration and agitation to maintain optimal conditions for mycelial growth throughout the cultivation period. This continuous action prevents growth stagnation and achieves both structural coherence and reduced cultivation time by maintaining peak metabolic activity.
3Quantity of substance
If textured soy protein technology is used, then plant-based meat alternatives can be produced, but the products lack high protein content and desirable fiber alignment
Solution Approach 1:
The patent replaces mechanical texturing methods with controlled fermentation processes that naturally produce aligned mycelial structures. The fungal hyphae self-organize into fiber-like structures during fermentation, eliminating the need for intensive mechanical processing while achieving high protein content and desirable fiber alignment simultaneously.
Solution Approach 2:
The final product combines mycelial biomass with minimal additives to create a composite material that leverages the natural structural properties of fungal hyphae. This approach achieves high protein content (30-40%) and fiber alignment without relying on plant-based protein extrusion, offering superior nutritional profile and texture.
4Quantity of substance
If fungal biomass is produced with high protein content, then nutritional value increases, but additional ingredients and processing requirements increase
Solution Approach 1:
The patent extracts and removes unnecessary components through simple filtration and rinsing steps, isolating the high-protein mycelial biomass from the fermentation medium. This extraction approach achieves high protein concentration (30-40%) in the final product while keeping processing complexity low by using straightforward separation techniques rather than complex purification systems.
Solution Approach 2:
The fermentation medium and filtration materials are designed as single-use, disposable components that can be easily discarded after one use. This approach simplifies the overall processing system by eliminating the need for extensive cleaning and sterilization equipment, reducing device complexity while maintaining high protein content in the final product.
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 process yields a high-protein, low-calorie, low-fat food product with a texture similar to chicken breast, using 95% mycelial biomass and minimal additives, offering environmental benefits and reduced resource consumption.
Implementation Method 1
A process involving the cultivation of filamentous fungi like Rhizopus oligosporus in a solid medium, followed by fermentation
Implementation Method 2
filtration, rinsing, and inactivation, results in mycelial biomass
Data Source
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AI summary
The present invention refers to a mycelial biomass and its production process; The present invention also refers to a food product based on mycelial biomass with high nutritional property and low concentration of additional ingredients and its production process.