Food Materials Comprising Filamentous Fungal Particles and Membrane Bioreactor Design

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.

1 . A bioreactor, comprising:
 a container;   at least one membrane or mesh scaffold disposed within or on a surface of the container, the at least one membrane or mesh scaffold comprising a first surface and a second surface;   a feedstock for the growth of a filamentous fungus, contacting the first surface of the at least one membrane or mesh scaffold; and   a filamentous fungus inoculum, disposed on either the first surface or the second surface of the at least one membrane or mesh scaffold,   wherein, upon culturing the inoculum in the bioreactor, a biomat of the filamentous fungus forms on the second surface of the at least one membrane or mesh scaffold after a biomat growth period.   
     
     
         2 . The bioreactor of  claim 1 , wherein the container is a bag, wherein the first and second surfaces of the at least one membrane or mesh scaffold are first and second surfaces of at least a portion of the bag. 
     
     
         3 . The bioreactor of  claim 1 , wherein the feedstock is subjected to a positive or negative pressure imparted on a side of the feedstock opposite at least one of the first surface and the second surface of the at least one membrane or mesh scaffold. 
     
     
         4 . The bioreactor of  claim 1 , further comprising cyanobacteria, wherein the cyanobacteria provide at least one of oxygen gas and carbon to promote the growth of the biomat. 
     
     
         5 . The bioreactor of  claim 1 , wherein at least one of the following is true:
 a density of the biomat is at least about 0.05 grams per cubic centimeter; and   a density of the biomat after drying is at least about 0.01 grams per cubic centimeter.   
     
     
         6 . The bioreactor of  claim 1 , wherein the biomat comprises at least one layer. 
     
     
         7 . The bioreactor of  claim 1 , wherein the biomat has a tensile strength of at least about 3 kilopascals or at least about 30 grams-force per square centimeter. 
     
     
         8 . The bioreactor of  claim 7 , wherein the biomat has a tensile strength of at least about 100 kilopascals or at least about 1,020 grams-force per square centimeter. 
     
     
         9 . The bioreactor of  claim 1 , wherein the at least one membrane or mesh scaffold 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. 
     
     
         10 . The bioreactor of  claim 1 , wherein the at least one membrane or mesh scaffold comprises at least one material selected from the group consisting of polypropylene fabrics, polytetrafluoroethylene fabrics, and a nylon net filter. 
     
     
         11 . The bioreactor of  claim 1 , wherein the at least one membrane or mesh scaffold comprises at least one of a glass fiber material and a porous ceramic material. 
     
     
         12 . The bioreactor of  claim 1 , wherein an average pore size of the at least one membrane or mesh scaffold is between about 0.2 μm and about 25 μm. 
     
     
         13 . The bioreactor of  claim 12 , wherein an average pore size of the at least one membrane or mesh scaffold is between about 5 μm and about 11 μm. 
     
     
         14 . The bioreactor of  claim 1 , wherein the container is enclosed and substantially airtight, wherein the container encloses a gas headspace into which the biomat grows. 
     
     
         15 . The bioreactor of  claim 1 , wherein the biomat separates from the at least one membrane or mesh scaffold spontaneously. 
     
     
         16 . The bioreactor of  claim 1 , wherein, when the biomat is removed from the at least one membrane or mesh scaffold, a new inoculum of filamentous fungi remains on the at least one membrane or mesh scaffold. 
     
     
         17 . The bioreactor 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. 
     
     
         18 . The bioreactor 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. 
     
     
         19 . The bioreactor of  claim 1 , wherein the filamentous fungus is selected from the group consisting of strain  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.  columbinus  (blue oyster),  Tuber borchii, Morchella esculenta, Morchella conica, Morchella importuna, Sparassis crispa  (cauliflower),  Fusarium venenatum, Fusarium  strain MK7 (ATCC Accession Deposit No. PTA-10698),  Disciotis venosa, Cordyceps militaris, Trametes versicolor, Ganoderma lucidum, Flammulina velutipes, Lentinula edodes, Pleurotus djamor, Pleurotus ostreatus, Leucoagaricus holosericeus, Calvatia fragilis, Handkea utriformis , and  Pholiota adiposa.    
     
     
         20 . The bioreactor of  claim 1 , wherein the feedstock comprises at least one of feces of an animal and urine of an animal. 
     
     
         21 . The bioreactor of  claim 20 , wherein the animal is a human. 
     
     
         22 . The bioreactor of  claim 1 , wherein the at least one membrane or mesh scaffold is a single composite membrane or mesh scaffold, wherein the first surface comprises a first material and the second surface comprises a second material. 
     
     
         23 . The bioreactor of  claim 1 , wherein the at least one membrane or mesh scaffold comprises at least a first membrane or mesh scaffold and a second membrane or mesh scaffold, wherein the first surface is a surface of the first membrane or mesh scaffold and the second surface is a surface of the second membrane or mesh scaffold. 
     
     
         24 . The bioreactor of  claim 23 , wherein the first and second membranes or mesh scaffolds are in physical contact with each other. 
     
     
         25 . The bioreactor of  claim 1 , further comprising 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. 
     
     
         26 . The bioreactor of  claim 25 , wherein a second gas produced during growth of the biomat is selectively separated into a gas headspace on a second side of the selective gas-permeable membrane. 
     
     
         27 . The bioreactor of  claim 1 , wherein the feedstock is a liquid feedstock comprising a carbon source and a nitrogen source. 
     
     
         28 . The bioreactor of  claim 1 , wherein the biomat can be harvested substantially intact from the second surface of the at least one membrane or mesh scaffold.