EU project explores the potential for fungal fermentation to produce food protein
Researchers at the Danish Technological Institute are exploring how super mushrooms can meet the strong demand for bio-based goods and alternative protein sources.
Edible mushrooms can be used to ferment residual streams from agriculture, so that what would otherwise go to waste can be upcycled into new products. The fungi live in a bioreactor, “eat” the waste streams they are fed with and convert it into biomass. The waste streams can be, for example, residues from sugar beet production, surplus grain from beer brewing and fruit peels, which are pre-treated before the fungi are given it as feed.
“You can compare it to kombucha brewing, where you feed a fungal bacterial culture with sugar. In the EU project Zest, the culture consists of fungal strains that convert the agricultural residues into biomass, which we can use directly or extract fungal protein and chitin from, which are used in eg medicine, food and bioplastics, says senior project manager Xiaoru Hou from the Danish Technological Institute. As the fungi are fed with side streams from agriculture and food production, and parts of the bacterial culture are recycled, the production method contributes to zero waste and circular economy.
“At the same time, the process requires only small amounts of water compared to more traditional protein production, while greenhouse gas emissions are also significantly lower. The result is a more sustainable and cost-effective method of protein production, which at the same time has a high level of food safety,” says project coordinator and head of centre Anne Christine Hastrup from the Danish Technological Institute.
Compared to plant protein, mushroom protein is easier for the human body to digest, according to the researchers. They also note, the fungi also provide vitamins B12 and D, which enrich the new foods that the fungal proteins are part of. The mushroom proteins have a neutral flavour profile due to their cell structure and different textures.
“We will optimise the entire production process by screening the most suitable waste products from agriculture and food production together with different fungal strains. We also specially design new bioreactors for the fungal fermentation. Last but not least, we are developing AI-based process modelling to monitor, analyse data, control and optimise production parameters,” says Anne Christine Hastrup.
AI is a key point in the development of the fungal protein of the future. The Danish Technological Institute uses advanced AI technologies to optimize the fermentation process – specifically by monitoring and controlling fermentation conditions in real time using data from many sensors in the bioreactors.
“In the ZEST project, we develop machine learning models based on parameters such as temperature, pH, oxygen levels and nutrient concentrations. We use hybrid models that combine traditional models of fungal growth with AI models trained on experimental data. The models can predict how the fungi behave on different agricultural residues and help fine-tune the bioreactor for optimal growth conditions, says Kristian Damlund Gregersen from the Danish Technological Institute.
AI-based process modelling has another advantage: a more sustainable production. The large data basis and the continuous adjustments make it possible to optimise yields, reduce waste, minimise energy consumption and ensure high quality of the end products.
The development of the new super mushrooms is partly taking place in the Danish Technological Institute’s Biosolutions Technology Center. Here, companies and startups can test and develop everything from edible proteins and vitamins to bio-based materials and packaging. All of this is based on biomass produced in the centre’s fermentation tanks and bioreactors using microorganisms – not least fungi or via biorefining in hydrolysis tanks.
