Water reclamation and value-added animal feed from corn-ethanol stillage by fungal processing

Biovalorization of brewer's spent grain as single-cell protein through coupling organosolv pretreatment and fungal cultivation

Brewer's spent grain (BSG) is a clean byproduct from the food sector, comprising 85% of the brewing process solid byproducts. BSG is mainly used as low-quality animal feed and often ends up in landfills due to its short shelf life. However, considering its abundant availability and high nutritional content, BSG holds the potential for biorefineries to produce valuable products. The recalcitrant nature of BSG poses a challenge, requiring pretreatment steps. Therefore, this study focused on valorizing BSG obtained from organosolv pretreatment by producing food- and feed-grade single-cell protein (SCP). The BSG was subject to organosolv pretreatment at 180C for 2 h with 50% v/v ethanol as solvent. Filamentous fungi N. intermedia and A. oryzae were cultivated on as-received and different fractions of organosolv-treated BSG to evaluate the effect of factors such as pretreatment, fungal strain, pretreated fraction content, and substrate loading on fungal biomass yield, biomass composition (protein content), and metabolite production. A. oryzae cultivation on all tested substrates yielded 7%-40% more biomass than N. intermedia. Cultivating A. oryzae on organosolv liquor resulted in the highest biomass protein content (44.8% ± 0.7%) with a fungal biomass concentration of 5.1 g/L. A three-fold increase in the substrate loading increased the ethanol-to-substrate yield by 50%, while protein content was decreased by 23%. Finally, a biorefinery concept was proposed to integrate the organosolv pretreatment of BSG with fungal cultivation for maximum yield of SCP while obtaining other products such as lignin and ethanol, providing a sustainable rout for managing BSG.

Valorization of vinasse and whey to protein and biogas through an environmental fungi-based biorefinery

Vinasse and whey are wastewaters that are produced in large quantities in the sugar-to-ethanol and dairy industries, respectively. They pose a considerable threat to the environment due to the high concentration of nutrients and COD. In this study, the potential of producing protein-rich fungal biomass and biomethane from vinasse and whey through a two-stage biorefinery was examined. In the first stage, an edible and safe for human filamentous fungus, Neurospora intermedia, was cultivated on these wastewaters. To maximize the fungal biomass yield, the cultivation parameters, i.e., pH, vinasse to whey ratio, incubation time, and nutrients supplementation, were optimized. The highest yield of 12.0 g biomass per L of wastewaters was obtained by cultivation at pH 6.5 and vinasse to whey ratio of 25:75 (v/v) for 96 h with nitrogen source supplementation. The N. intermedia biomass contained about 45% protein and noticeable essential amino acid contents, comparable to commercial sources of protein for aquatic feed such as soybean meal and fishmeal. In the second stage, the effluent of fungal cultivation was anaerobically digested to produce 425 mL/g VS biomethane. Overall, 1 m³ of wastewater yielded 5.4 kg crude protein and 10.3 m³ methane, accompanied by 93.3% COD removal.

Production of L-carnitine-enriched edible filamentous fungal biomass through submerged cultivation

The edible filamentous fungi are hot candidate for future supply of functional food and feed with e.g. protein, essential amino acids, and compounds with immunostimulant activity. L-carnitine that plays a crucial role in energy metabolism represents a functional compound normally produced by Zygomycetes filamentous fungus Rhizopus oligosporus in solid-state fermentation. The present study provides the first insights on production of L-carnitine-enriched edible fungal biomass through submerged cultivation of several Ascomycetes and Zygomycetes including Aspergillus oryzae, Neurospora intermedia, Rhizopus oryzae, and Rhizopus oligosporus. A. oryzae with 3 mg L-carnitine yield per gram of fungal biomass, indicates great potential on production of this bioactive compound which is remarkably higher than the other tested fungi in this work and also previous studies. In addition to fungal strain, other factors such as cultivation time and presence of yeast extract were found to play a role. Further studies on submerged growth optimization of A. oryzae in both high-quality recipes and in medium based on low-value substrates are proposed in order to clarify its potential for production of L-carnitine-enriched fungal biomass.

Integrated process for protein, pigments, and biogas production from baker's yeast wastewater using filamentous fungi

Baker's yeast production industry generates large quantities of high chemical oxygen demand (COD) wastewater. The integration of baker's yeast wastewater (BYW) for an innovative two-step waste biorefinery process by producing protein-rich fungal biomass and biogas along with COD and nutrients removal was the main object of the present research. In the first step, fungal biomass production from BYW was investigated using four species of filamentous fungi. The maximum biomass yield of 5.13 g/L BYW containing 43.8% mycoprotein and 36.3% COD removal was achieved by A. oryzae. In the second step, to produce biogas and further remove organic matter, the effluent of fungal fermentation was subjected to anaerobic digestion and COD removal between 22.4 and 44.2% was obtained. Overall, 1 m³ of BYW yielded 5.13 kg of protein-rich biomass and 1.42 m³ of methane. Additionally, pigment production using N. intermedia was investigated, and 1.54 mg carotenoids/g biomass was produced.

Cereal processing waste, an environmental impact and value addition perspectives: A comprehensive treatise

This review is to describe various methods used for the treatment of cereal processing wastes and their efficiency to reduce environmental issues. Physico-chemical and biological methods have great potential for the treatment of cereal industrial waste. These methods can be used alone or in combination with effective treatment. Physico-chemical treatments are mostly employed for the pretreatment of cereal processing wastes that helps in reduced sludge formation during biological treatments. Biological treatments are mostly used owing to their high efficiency in removing pollutants, and less expensive than physico-chemical treatments. However, these treatments consume more time as compared to physico-chemical treatments. These treatments also proved to be efficient for a high rate of cereal waste conversion into value-added products. Thus, cereal industrial waste can result in value-added products such as biohydrogen, bioethanol, butanol, biogas and biocoal as biofuels, industrial valued enzymes, biomass, biofertilizer, proteins, organic acids, polysaccharides and few others.

Treatment of thin stillage by Aspergillus oryzae and its effect on alcoholic fermentation in syrup liquid

The microbial degradation of thin stillage for environment-friendly treatment has been studied extensively in recent years, and useful compounds in the treated-thin stillage are expected to be utilized in the subsequent fermentation. In this study, an Aspergillus oryzae H18, suitable for growing in thin stillage, was isolated from soil and served to degrade the organic matter in thin stillage, with the increase in pH (from 3·75 to 4·8) and decrease in chemical oxygen demand (COD, 81·3% removal rate). The effect of thin stillage as backset water after degradation of the strain H18 on alcohol production in syrup liquid was investigated. Compared with zero addition of thin stillage, the alcohol yield in mixed syrup liquid increased by 8·6% when the concentration of treated-thin stillage was 20%. After the addition of nutrients at proper concentration (0·5% urea, 1% molasses, 0·25% NaCl, 0·2% NaH₂ PO₄ , 0·3% MgSO₄ and 0·25% CaCl₂ ) in thin stillage, the alcohol yield in yeast fermentation was increased by 32·7% when mixed syrup liquid (with 40% thin stillage treated by H18) was employed, in comparison to control group without thin stillage addition. Meanwhile, the fermentation time was shortened, and alcohol production rate was enhanced.

New Insights on Protein Recovery from Olive Oil Mill Wastewater through Bioconversion with Edible Filamentous Fungi

Olive oil mills represent an important sector in the Mediterranean Sea Basin but also an environmental hazard due to untreated wastewater. Recovery of nutrients from olive oil mill wastewater (OMWW) as protein-rich microbial biomass can produce novel feed and reduce its chemical oxygen demand; however, low-protein containing products have been reported. New strategies leading to higher protein-containing fungal biomass could renew the research interest on bioconversion for pollution mitigation of OMWW. In this work, through cultivation of edible filamentous fungi (Aspergillus oryzae, Neurospora intermedia, and Rhizopus delemar), a link between the protein content in the originated fungal biomass, and the addition of nitrogen and medium dilution was established. Addition of nitrogen in the form of NaNO3 reduced the cultivation time from 96 h to 48 h while achieving a similar biomass mass concentration of 8.43 g/L and increased biomass protein content, from w = 15.9% to w = 29.5%. Nitrogen addition and dilution of OMWW, and consequent reduction of suspended solids, led to an increase in the protein content to up to w = 44.9%. To the best of our knowledge, the protein contents achieved are the highest reported to date and can open new research avenues towards bioconversion of OMWW using edible filamentous fungi.

Utilization of food waste-derived volatile fatty acids for production of edible Rhizopus oligosporus fungal biomass

Rhizopus oligosporus is an edible filamentous fungus that can contribute to meet the growing demand for single-cell protein. Volatile fatty acids (VFAs) are favorable potential substrates for producing R. oligosporus biomass due to their capacity to be synthesized from a wide range of low-value organic solid wastes via anaerobic digestion. The goal of this work was to cultivate R. oligosporus using food waste-derived VFAs as the sole carbon source. To maintain the requisite low substrate concentrations, the fed-batch cultivation technique was applied. This resulted in a four-fold improvement in biomass production relative to standard batch cultivation. Maximum biomass yield of 0.21 ± 0.01 g dry biomass/g VFAs _{COD eq. consumed}, containing 39.28 ± 1.54% crude protein, was obtained. In the bubble-column bioreactors, the complete uptake of acetic acid was observed, while the consumptions of caproic and butyric acids reached up to 97.64% and 26.13%, respectively.

Conversion of fish processing wastewater into fish feed ingredients through submerged cultivation of Aspergillus oryzae

Abstract

Fish processing towards production of fillet gives rise to wastewater streams that are ultimately directed to biogas production and/or wastewater treatment. However, these wastewater streams are rich in minerals, fat, and proteins that can be converted to protein-rich feed ingredients through submerged cultivation of edible filamentous fungi. In this study, the origin of wastewater stream, initial pH, cultivation time, and extent of washing during sieving, were found to influence the amount of recovered material from the wastewater streams and its protein content, following cultivation with Aspergillus oryzae. Through cultivation of the filamentous fungus in sludge, 330 kg of material per ton of COD were recovered by sieving, corresponding to 121 kg protein per ton of COD, while through its cultivation in salt brine, 210 kg of material were recovered per ton of COD, corresponding to 128 kg protein per ton of COD. Removal ranges of 12–43%, 39–92%, and 32–66% for COD, total solids, and nitrogen, respectively, were obtained after A. oryzae growth and harvesting in the wastewater streams. Therefore, the present study shows the versatility that the integration of fungal cultivation provides to fish processing industries, and should be complemented by economic, environmental, and feeding studies, in order to reveal the most promising valorization strategy.

Graphic abstract

Bioprocessing strategies to increase the protein fraction of Rhizopus oryzae biomass using fish industry sidestreams

The sidestreams produced during fish processing end in a separation tank where the resulting fractions follow biogas production or wastewater treatment. These streams can alternatively be used for production of protein-rich fungal biomass for e.g. fish feed applications, a product in increasing demand. These streams and upper streams originated during fish processing were used in this study for production of biomass using the edible filamentous fungus Rhizopus oryzae. The COD of the streams varied between 11 and 54 kg/m3 and, after fungal conversion of organic matter into protein-rich biomass and separation, a reduction of 34-69% was achieved. The stream origin had an effect on the final production and composition of the fungal biomass: 480 kg of biomass containing 33% protein per ton of COD were produced after cultivation in the separation tank streams, while 220 kg of biomass containing 62% protein per ton of COD were produced in upper sidestreams with lower amounts of suspended solids. Changing the initial pH (6.1-6.5) to 5.0 had a negative influence on the amount of biomass produced while medium supplementation had no influence. Thus, fish processing sidestreams can be diverted from biogas production and wastewater treatment to the production of protein-rich biomass for feed applications.

N. de Moura Bell JM. Bioconversion of cheese whey permeate into fungal oil by Mucor circinelloides

BACKGROUND

Oleaginous fungi are efficient tools to convert agricultural waste streams into valuable components. The filamentous fungus Mucor circinelloides was cultivated in whey permeate, a byproduct from cheese production, to produce an oil-rich fungal biomass. Response surface methodology was used to optimize the fermentation conditions such as pH and temperature for increased biomass yield and lipid accumulation. Quantification and characterization of the fungal biomass oil was conducted.

RESULTS

Upstream lactose hydrolysis of the whey permeate increased the biomass yield from 2.4 to 7.8 (g dry biomass/L) compared to that of non-hydrolyzed whey permeate. The combination of low pH (4.5) and pasteurization minimized microbial competition, thus favoring fungal growth. A central composite rotatable design was used to evaluate the effects of temperature (22.4-33.6 °C) and a lower pH range (3.6-4.7) on biomass yield and composition. The highest biomass yield and oil content was observed at high temperature (33.6 °C), while the pH range evaluated had a less pronounced effect. The predictive model was validated at the optimal conditions of 33.6 °C and pH 4.5. The fungal biomass yield plateaued at 9 g dry cell weight per liter, while the oil content and lipid yield reached a maximum of 24% dry biomass and 2.20 g/L, respectively, at 168 h. Triacylglycerides were the major lipid class (92%), which contained predominantly oleic (41%), palmitic (23%), linoleic (11%), and γ-linolenic acid (9%).

CONCLUSIONS

This study provided an alternative way of valorization of cheese whey permeate by using it as a substrate for the production of value-added compounds by fungal fermentation. The fatty acid profile indicates the suitability of M. circinelloides oil as a potential feedstock for biofuel production and nutraceutical applications.

Use of Organic Wastes and Industrial By-Products to Produce Filamentous Fungi with Potential as Aqua-Feed Ingredients

Organic-rich waste and industrial by-product streams, generated in enormous amounts on a daily basis, contain substantial amounts of nutrients that are worthy of recovery. Biological conversion of organic-waste streams using filamentous fungi is a promising approach to convert nutrients into value-added bioproducts, such as fungal biomass. High-protein fungal biomass contains different kinds and levels of amino acids, fatty acids, immunostimulants, antioxidants, pigments, etc., which make it a potential choice for application in animal feed supplementation. Considering the challenges long faced by the aquaculture industry in fishmeal production due to the increasing prices and environmental concerns, the aquaculture industry is forced to provide alternative protein-rich sources to replace conventional fishmeal. In this review, the possibilities of utilization of filamentous fungi biomass cultivated on organic-rich waste streams, as an alternative nutrient source in fish feed, were thoroughly reviewed.

Ethanol fermentation characteristics of recycled water by Saccharomyces cerevisiae in an integrated ethanol-methane fermentation process

An process of integrated ethanol-methane fermentation with improved economics has been studied extensively in recent years, where the process water used for a subsequent fermentation of carbohydrate biomass is recycled. This paper presents a systematic study of the ethanol fermentation characteristics of recycled process water. Compared with tap water, fermentation time was shortened by 40% when mixed water was employed. However, while the maximal ethanol production rate increased from 1.07g/L/h to 2.01g/L/h, ethanol production was not enhanced. Cell number rose from 0.6×10(8) per mL in tap water to 1.6×10(8) per mL in mixed water but although biomass increased, cell morphology was not affected. Furthermore, the use of mixed water increased the glycerol yield but decreased that of acetic acid, and the final pH with mixed water was higher than when using tap water.

Ethanol, feed components and fungal biomass production from field bean (Vicia faba var. equina) seeds in an integrated process

The use of field beans, a non-food leguminous crop, was studied for ethanol, feed components and fungal biomass production. The seeds were hydrolyzed using enzymes or with combination of acid (H3PO4) and alkaline (Ca(OH)2) pretreatment and enzymatic hydrolysis. Fermentation by Saccharomyces cerevisiae, with or without removal of suspended solids, yielded 38.3-42.5gL(-1) ethanol (71.3-79.2% efficiency). The filtration residues contained ca. 247-326gkg(-1) crude protein, 10.6-15.5% acid detergent fiber and 19.9-29.1% neutral detergent fiber. They were enriched in phenolics (by up to 93.4%) and depleted in condensed tannin (by up to 59.3%) in comparison to the raw material. The thin stillages were used for cultivation of edible fungus Neurospora intermedia which produced 8.5-15.9gL(-1) ethanol and 4.8-16.2gL(-1) biomass containing over 62% protein. The mass balances showed that fermentation of unfiltered mashes was more efficient yielding up to 195.9gkg(-1) ethanol and 84.4% of protein recovery.

Ethanol and Protein from Ethanol Plant By-Products Using Edible Fungi Neurospora intermedia and Aspergillus oryzae

Feasible biorefineries for production of second-generation ethanol are difficult to establish due to the process complexity. An alternative is to partially include the process in the first-generation plants. Whole stillage, a by-product from dry-mill ethanol processes from grains, is mostly composed of undegraded bran and lignocelluloses can be used as a potential substrate for production of ethanol and feed proteins. Ethanol production and the proteins from the stillage were investigated using the edible fungi Neurospora intermedia and Aspergillus oryzae, respectively. N. intermedia produced 4.7 g/L ethanol from the stillage and increased to 8.7 g/L by adding 1 FPU of cellulase/g suspended solids. Saccharomyces cerevisiae produced 0.4 and 5.1 g/L ethanol, respectively. Under a two-stage cultivation with both fungi, up to 7.6 g/L of ethanol and 5.8 g/L of biomass containing 42% (w/w) crude protein were obtained. Both fungi degraded complex substrates including arabinan, glucan, mannan, and xylan where reductions of 91, 73, 38, and 89% (w/v) were achieved, respectively. The inclusion of the current process can lead to the production of 44,000 m³ of ethanol (22% improvement), around 12,000 tons of protein-rich biomass for animal feed, and energy savings considering a typical facility producing 200,000 m³ ethanol/year.