Food materials comprising filamentous fungal particles and membrane bioreactor design

Patent metadata

Field	Value
Publication number	US-11432575-B2
Application number	US-202016803667-A
Country	US
Kind code	B2
Filing date	Feb 27, 2020
Priority date	Feb 27, 2019
Publication date	Sep 6, 2022
Grant date	Sep 6, 2022

Abstract

Methods of production of edible filamentous fungal biomat formulations are provided as standalone protein sources and/or protein ingredients in foodstuffs as well as a one-time use or repeated use self-contained biomat reactor comprising a container with at least one compartment and placed within the compartment(s), a feedstock, a fungal inoculum, a gas-permeable membrane, and optionally a liquid nutrient medium.

First claim

The invention claimed is:

1. A method for producing a biomat of a filamentous fungus, comprising:
inoculating a filamentous fungus in a bioreactor, wherein the bioreactor comprises:
a container;
at least one membrane disposed within or on a surface of the container, the at least one membrane comprising a first surface and a second surface, wherein either or both of the first and second surfaces are adapted to receive thereon the inoculum of the filamentous fungus; and
a liquid feedstock for the growth of a filamentous fungus, contacting the first surface of the at least one membrane;

culturing the filamentous fungus to form the biomat on a surface of the at least one membrane of the bioreactor; and
harvesting the biomat,
wherein, upon harvesting, the biomat has a tensile strength of at least 30 g/cm 2 .

2. A method for producing a biomat of a filamentous fungus, comprising:
inoculating a filamentous fungus in a bioreactor, wherein the bioreactor comprises:
a container;
at least one mesh scaffold disposed within or on a surface of the container, the at least one mesh scaffold comprising a first surface and a second surface, wherein either or both of the first and second surfaces are adapted to receive thereon the inoculum of the filamentous fungus; and
a liquid feedstock for the growth of a filamentous fungus, contacting the first surface of the mesh scaffold;

culturing the filamentous fungus to form the biomat on a surface of the at least one mesh scaffold of the bioreactor; and
harvesting the biomat,
wherein, upon harvesting, the biomat has a tensile strength of at least 30 g/cm 2 .

3. The method of claim 1 , wherein the container is a bag, wherein the first and second surfaces of the at least one membrane are first and second surfaces of at least a portion of the bag.

4. The method of claim 1 , wherein the feedstock is subjected to a positive or negative pressure imparted on a side of the feedstock opposite the first surface of the at least one membrane.

5. The method of claim 4 , wherein the positive or negative pressure facilitates the inoculating step.

6. The method of claim 1 , further comprising providing cyanobacteria in the bioreactor, wherein the cyanobacteria provide at least one of oxygen gas and carbon to promote growth of the biomat.

7. The method of claim 1 , wherein at least one of the following is true:
i) a density of the biomat after harvesting is at least 0.6 grams per cubic centimeter; and
ii) a density of the biomat after harvesting and drying is at least 0.1 grams per cubic centimeter.

8. The method of claim 1 , wherein the biomat comprises at least one layer.

9. The method of claim 1 , wherein, during or after the harvesting step, the biomat has a tensile strength of at least 3 kilopascals or at least 30 grams-force per square centimeter.

10. The method of claim 9 , wherein, during or after the harvesting step, the biomat has a tensile strength of at least 100 kilopascals or at least 1,020 grams-force per square centimeter.

11. The method of claim 1 , wherein the at least one membrane comprises at least one polymer selected from the group consisting of polypropylenes, polytetrafluoroethylenes, polycarbonates, polyamides, cellulose acetate, polyvinylidene fluorides, mixed cellulose esters, polyethersulfones, polyethylenes, and polypyrroles.

12. The method of claim 1 , wherein the at least one membrane comprises at least one material selected from the group consisting of polypropylene fabrics, polytetrafluoroethylene fabrics, and a nylon net filter.

13. The method of claim 1 , wherein the at least one membrane comprises at least one of a glass fiber material and a porous ceramic material.

14. The method of claim 1 , wherein an average pore size of the at least one membrane is between about 0.2 μm and about 25 μm.

15. The method of claim 14 , wherein an average pore size of the at least one membrane is between about 5 μm and about 11 μm.

16. The method of claim 1 , wherein the container is enclosed and airtight, wherein the container encloses a gas headspace into which the biomat grows.

17. The method of claim 1 , wherein the biomat separates from the at least one membrane by self-harvesting.

18. The method of claim 1 , wherein, when the biomat is removed from the at least one membrane, filamentous fungus sufficient to re-inoculate the at least one membrane remains on the at least one membrane.

19. The method of claim 1 , wherein the filamentous fungus belongs to an order selected from the group consisting of Mucorales, Ustilaginales, Russulales, Polyporales, Agaricales, Pezizales and Hypocreales.

20. The method of claim 1 , wherein the filamentous fungus belongs to a family selected from the group consisting of Mucoraceae, Ustilaginaceae, Hericiaceae, Polyporaceae, Grifolaceae, Lyophyllaceae, Strophariaceae, Lycoperdaceae, Agaricaceae, Pleurotaceae, Physalacriaceae, Ophiocordycipitaceae , Tuberaceae, Morchellaceae , Sparassidaceae, Nectriaceae, Bionectriaceae , and Cordycipitaceae.

21. The method of claim 1 , wherein the filamentous fungus is selected from the group consisting of 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. columbines ( Blue oyster ), Tuber borchii, Morchella esculenta, Morchella conica, Morchella importuna, Sparassis crispa ( cauliflower ), Fusarium venenatum , strain MK 7 ( ATCC Accession Deposit No. PTA -10698), Disciotis venosa , and Cordyceps militaris Trametes versicolor, Ganoderma lucidum, Flammulina velutipes, Lentinula edodes, Pleurotus djamor, Pleurotus ostreatus , and Leucoagaricus spp.

22. The method of claim 1 , wherein the feedstock comprises at least one of feces of an animal and urine of an animal.

23. The method of claim 22 , wherein the animal is a human.

24. The method of claim 1 , wherein the at least one membrane is a single composite membrane, wherein the first surface comprises a first material and the second surface comprises a second material.

25. The method of claim 1 , wherein the at least one membrane comprises at least a first membrane and a second membrane, wherein the first surface is a surface of the first membrane and the second surface is a surface of the second membrane.

26. The method of claim 25 , wherein the first and second membranes are in physical contact with each other.

27. The method of claim 1 , wherein the bioreactor further comprises a selective gas-permeable membrane, wherein a first gas produced during growth of the biomat is selectively separated into a gas headspace on a first side of the selective gas-permeable membrane.

28. The method of claim 27 , wherein a second gas produced during growth of the biomat is selectively separated into a gas headspace on a second side of the membrane.

29. The method of claim 2 , wherein the mesh scaffold comprises a nylon material.

Assignees

• The Fynder Group Inc

Inventors

• Macur Richard Eugene
• Avniel Yuval Charles
• Black Renata Usaite
• Hamilton Maximilian Devane
• Harney Michael John
• Eckstrom Eleanore Brophy
• Kozubal Mark Andrew

Classifications

• C12M23/14

  Bags · CPC title

• A23V2002/00

  Food compositions, function of food ingredients or processes for food or foodstuffs · CPC title

• A21D13/064

  with modified protein content · CPC title

• A23G9/32

  characterised by the composition {containing organic or inorganic compounds} · CPC title

• A23C9/1315

  Non-milk proteins or fats; Seeds, pulses, cereals or soja; Fatty acids, phospholipids, mono- or diglycerides or derivatives therefrom; Egg products · CPC title