Valorization of Bread Waste to a Fiber- and Protein-Rich Fungal Biomass

Dry gel spinning of fungal hydrogels for the development of renewable yarns from food waste

BACKGROUND

Renewable materials made using environmentally friendly processes are in high demand as a solution to reduce the pollution created by the fashion industry. In recent years, there has been a growing trend in research on renewable materials focused on bio-based materials derived from fungi.

RESULTS

Recently, fungal cell wall material of a chitosan producing fungus has been wet spun to monofilaments. This paper presents a modification for the fungal monofilament spinning process, by the development of a benign method, dry gel spinning, to produce continuous monofilaments and twisted multifilament yarns, from fungal cell wall, that can be used in textile applications. The fungal biomass of Rhizopus delemar, grown using bread waste as a substrate, was subjected to alkali treatment with a dilute sodium hydroxide solution to isolate alkali-insoluble material (AIM), which mainly consists of the fungal cell wall. The treatment of AIM with dilute lactic acid resulted in hydrogel formation. The morphology of the hydrogels was pH dependent, and they exhibited shear thinning viscoelastic behavior. Dry gel spinning of the fungal hydrogels was first conducted using a simple lab-scale syringe pump to inject the hydrogels through a needle to form a monofilament, which was directly placed on a rotating receiver and left to dry at room temperature. The resulting monofilament was used to make twisted multifilament yarns. The process was then improved by incorporating a heated chamber for the quicker drying of the monofilaments (at 30⁰C). Finally, the spinning process was scaled up using a twin-screw microcompounder instead of the syringe pump. The monofilaments were several meters long and reached a tensile strength of 63 MPa with a % elongation at break of 14. When spinning was performed in the heated chamber, the tensile strength increased to 80 MPa and further increased to 103 MPa when a micro-compounder was used for spinning.

CONCLUSION

The developed dry gel spinning method shows promising results in scalability and demonstrates the potential for renewable material production using fungi. This novel approach produces materials with mechanical properties comparable to those of conventional textile fibers.

Mixed food waste valorization using a thermostable glucoamylase enzyme produced by a newly isolated filamentous fungus: A sustainable biorefinery approach

Food waste is a lucrative source of complex nutrients, which can be transformed into a multitude of bioproducts by the aid of microbial cell factories. The current study emphasizes isolating Glucoamylase enzyme (GA) producing strains that can effectively break down mixed food waste (MW), which serves as a substrate for biomanufacturing. The screening procedure relied heavily on the growth of isolated fungi on starch agar media, to specifically identify the microbes with the highest starch hydrolysis potential. A strain displayed the highest GA activity of 2.9 ± 0.14 U/ml which was selected and identified as Aspergillus fumigatus via molecular methods of identification. Exposure of the A. fumigatus with 200 mM Ethyl methanesulphonate (EMS) led to a 23.79% increase compared to the wild-type GA. The growth conditions like cultivation temperature or the number of spores in the inoculum were investigated. Further, maximum GA activity was exhibited at pH 5, 55 °C, and at 5 mM Ca2+ concentration. The GA showed thermostability, retaining activity even after long periods of exposure to temperatures as high as 95 °C. The improvement of hydrolysis of MW was achieved by Taguchi design where a maximum yield of 0.57 g g-1 glucose was obtained in the hydrolysate. This study puts forth the possibility that mixed food waste, despite containing spices and other microbial growth-inhibitory substances, can be efficiently hydrolyzed to release glucose units, by robust fungal cell factories. The glucose released can then be utilized as a carbon source for the production of value-added products.

Valorization of Food Waste into Single-Cell Protein: An Innovative Technological Strategy for Sustainable Protein Production

The rapidly increasing population and climate change pose a great threat to our current food systems. Moreover, the high usage of animal-based and plant-based protein has its drawbacks, as these nutritional sources require many hectares of land and water, are affected by seasonal variations, are costly, and contribute to environmental pollution. Single-cell proteins (SCPs) are gaining a lot of research interest due to their remarkable properties, such as their high protein content that is comparable with other protein sources; low requirements for land and water; low carbon footprint; and short production period. This review explores the use of food waste as a sustainable feedstock for the advancement of SCP processes. It discusses SCP studies that exploit food waste as a substrate, alongside the biocatalysts (bacteria, fungi, yeast, and microalgae) that are used. The operational setpoint conditions governing SCP yields and SCP fermentation routes are elucidated as well. This review also demonstrates how the biorefinery concept is implemented in the literature to improve the economic potential of "waste-to-protein" innovations, as this leads to the establishment of multiproduct value chains. A short section that discusses the South African SCP scenario is also included. The technical and economic hurdles facing second-generation SCP processes are also discussed, together with future perspectives. Therefore, SCP technologies could play a crucial role in the acceleration of a "sustainable protein market", and in tackling the global hunger crisis.

Upcycling of food waste streams to valuable biopigments pyocyanin and 1-hydroxyphenazine

Phenazines, including pyocyanin (PYO) and 1-hydroxyphenazine (1-HP) are extracellular secondary metabolites and multifunctional pigments of Pseudomonas aeruginosa responsible for its blue-green color. These versatile molecules are electrochemically active, involved in significant biological activities giving fitness to the host, but also recognized as antimicrobial and anticancer agents. Their wider application is still limited partly due to the cost of carbon substrate for production, which can be solved by the utilization of carbon from food waste within the biorefinery concept. In this study, a variety of food waste streams (banana peel, potato peel, potato washing, stale bread, yoghurt, processed meat, boiled eggs and mixed canteen waste) was used as sole nutrient source in submerged cultures of P. aeruginosa BK25H. Stale bread was identified as the most suitable substrate to support phenazine biopigments production and bacterial growth. This was further increased in 5-liter fermenter when on average 5.2 mg L-1 of PYO and 4.4 mg L-1 of 1-HP were purified after 24 h batch cultivations from the fermentation medium consisting of homogenized stale bread in tap water. Purified biopigments showed moderate antimicrobial activity, and showed different toxicity profiles, with PYO not being toxic against Caenorhabditis elegans, a free-living soil nematode up to 300 µg mL-1 and 1-HP showing lethal effects at 75 µg mL-1. Therefore, stale bread waste stream with minimal pretreatment should be considered as suitable biorefinery feedstock, as it can support the production of valuable biopigments such as phenazines.

Effects of fungal based bioactive compounds on human health: Review paper

Since the first years of history, microbial fermentation products such as bread, wine, yogurt and vinegar have always been noteworthy regarding their nutritional and health effects. Similarly, mushrooms have been a valuable food product in point of both nutrition and medicine due to their rich chemical components. Alternatively, filamentous fungi, which can be easier to produce, play an active role in the synthesis of some bioactive compounds, which are also important for health, as well as being rich in protein content. Therefore, this review presents some important bioactive compounds (bioactive peptides, chitin/chitosan, β-glucan, gamma-aminobutyric acid, L-carnitine, ergosterol and fructooligosaccharides) synthesized by fungal strains and their health benefits. In addition, potential probiotic- and prebiotic fungi were researched to determine their effects on gut microbiota. The current uses of fungal based bioactive compounds for cancer treatment were also discussed. The use of fungal strains in the food industry, especially to develop innovative food production, has been seen as promising microorganisms in obtaining healthy and nutritious food.

Filamentous fungi for sustainable vegan food production systems within a circular economy: Present status and future prospects

Filamentous fungi serve as potential candidates in the production of different value-added products. In the context of food, there are several advantages of using filamentous fungi for food. Among the main advantages is that the fungal biomass used food not only meets basic nutritional requirements but that it is also rich in protein, low in fat, and free of cholesterol. This speaks to the potential of filamentous fungi in the production of food that can substitute animal-derived protein sources such as meat. Moreover, life-cycle analyses and techno-economic analyses reveal that fungal proteins perform better than animal-derived proteins in terms of land use efficiency as well as global warming. The present article provides an overview of the potential of filamentous fungi as a source of food and food supplements. The commercialization potential as well as social, legal and safety issues of fungi-based food products are discussed.

Fungal protein

This chapter reviews the uses of processed fungal cells as protein-rich foods in substitution to meat. Yeasts, mushrooms, and filamentous fungi have long been part of the human diet, improving the nutritional quality and taste of different foods. Recently, because of the populational growth and environmental impact caused by animal farming, the use of animal-derived protein has been raising concerns in public and scientific debates. Fungal biomass represents a nutritious, safe meat alternative that can help society in the reduction of greenhouse gases emissions and improve public health. Additionally, it provides all essential amino acids and has an interesting fatty acid profile. Current research is involved in finding new strains with improved efficiency, the investigation of new substrates (especially agro-industrial wastes) to reduce the environmental impact, and the development of new formulations to use mycoprotein in different dishes.

High-Efficiency Conversion of Bread Residues to Ethanol and Edible Biomass Using Filamentous Fungi at High Solids Loading: A Biorefinery Approach

Bread residues represent a significant fraction of retail food wastes, becoming a severe environmental challenge and an economic loss for the food sector. They are, however, an attractive resource for bioconversion into value-added products. In this study, the edible filamentous fungi Neurospora intermedia and Aspergillus oryzae were employed for the production of bioethanol and high-protein biomass by cultivation on enzymatically liquefied bread-waste medium at 150 g/L solids. The fermentation of hydrolysate by N. intermedia resulted in the ethanol titer of 32.2 g/L and biomass yield of 19.2 g/L with ca. 45% protein. However, the fermentation ended with a considerable amount of residual fermentable sugars; therefore, the liquid medium after the first fermentation was distilled and fermented again by two fungal strains (N. intermedia and A. oryzae). The fermentations resulted in the production of additional ethanol and biomass. A. oryzae showed better performance in the production of biomass, while the other strain yielded more ethanol. The final products’ yield ranged 0.29–0.32 g EtOH/g and 0.20–0.22 g biomass/g bread waste depending on the strain used in the second fermentation. The study shows that valorization of bread residuals by fungi is a promising option for the production of biofuels and foodstuff within the circular bioeconomy approach.

Turning food waste to antibacterial and biocompatible fungal chitin/chitosan monofilaments

Here, cell wall of a zygomycete fungus, Rhizopus delemar, grown on bread waste was wet spun into monofilaments. Using the whole cell wall material omits the common chitosan isolation and purification steps and leads to higher material utilization. The fungal cell wall contained 36.9% and 19.7% chitosan and chitin, respectively. Solid state NMR of the fungal cell wall material confirmed the presence of chitosan, chitin, and other carbohydrates. Hydrogels were prepared by ultrafine grinding of the cell wall, followed by addition of lactic acid to protonate the amino groups of chitosan, and subsequently wet spun into monofilaments. The monofilament inhibited the growth of Bacillus megaterium (Gram+ bacterium) and Escherichia coli (Gram- bacterium) significantly (92.2% and 99.7% respectively). Cytotoxicity was evaluated using an in vitro assay with human dermal fibroblasts, indicating no toxic inducement from exposure of the monofilaments. The antimicrobial and biocompatible fungal monofilaments, open new avenues for sustainable biomedical textiles from abundant food waste.

Mucoromycota fungi as powerful cell factories for modern biorefinery

Biorefinery employing fungi can be a strategy for valorizing low-cost rest materials, by-products and wastes into several valuable bioproducts through the fungal fermentation. Mucoromycota fungi are soil fungi with a highly versatile metabolic system that positions them as powerful microbial cell factories for biorefinery applications. Lipids, pigments, chitin/chitosan, polyphosphates, ethanol, organic acids and enzymes are main Mucoromycota products that can be refined from the fermentation process and applied in nutrition, chemical or biofuel industries. In addition, Mucoromycota biomass can be used as it is for specific purposes, such as feed. Mucoromycota fungi can be employed in developing co-production processes, whereby several intra- and extracellular products are simultaneously formed in a single fermentation process, and, thus, economic viability of the process can be improved. This mini review provides a comprehensive overview over the recent advances in the production of valuable metabolites by Mucoromycota fungi and fermentation strategies which could be potentially applied in the industrial biorefinery settings. KEY POINTS: • Biorefineries utilizing Mucoromycota fungi as production cell factories can provide a wide range of bioproducts. • Mucoromycota fungi are able to perform co-production of various metabolites in a single fermentation process. • Versatile metabolism of Mucoromycota allows valorization of a various low-cost substrates such as wastes and rest materials.

Filamentous Fungus Aspergillus oryzae for Food: From Submerged Cultivation to Fungal Burgers and Their Sensory Evaluation-A Pilot Study

New food sources are explored to provide food security in sustainable ways. The submerged fermentation of edible filamentous fungi is a promising strategy to provide nutritious and affordable food that is expected to have a low environmental impact. The aim of the current study was to assess the novel use of Aspergillus oryzae cultivated in submerged fermentation on oat flour as a source for food products that do not undergo secondary fermentation or significant downstream processing. The fungus was cultivated in a pilot-scale airlift bioreactor, and the biomass concentration and protein content of the biomass were assessed. A tasting with an untrained panel assessed consumer preferences regarding the taste and texture of minimally processed vegetarian and vegan burger patties made from the biomass, and how the patties fared against established meat-alternative-based patties. The cultivation of Aspergillus oryzae resulted in a yield of 6 g/L dry biomass with a protein content of 37% on a dry weight basis. The taste and texture of the minimally processed fungal burger patties were to the liking of some participants. This was also reflected in diverse feedback provided by the participants. The cultivation of the fungus on oat flour and its utilization in developing burger patties shows its promising potential for the production of nutritious food. The applications of the fungus can be further developed by exploring other favorable ways to texture and season this relatively new functional food source to the preferences of consumers.