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Filamentous/solid fermentation

Filamentous/solid fermentation. Tempeh Quorn Soya sauce Commercial mushrooms Cheese Penicillin. Agricultural waste. 2.1 x 10 12 kg per year cereal straw, sugarcane and sugar beet residue primarily cellulose and lignins low digestibility (40-60%) even for herbivores

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Filamentous/solid fermentation

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  1. Filamentous/solid fermentation • Tempeh • Quorn • Soya sauce • Commercial mushrooms • Cheese • Penicillin

  2. Agricultural waste • 2.1 x 1012 kg per year • cereal straw, sugarcane and sugar beet residue • primarily cellulose and lignins • low digestibility (40-60%) even for herbivores • subsistence nutrition • leads to low growth rates, and need for feed supplements (especially lysine!)

  3. Tempeh – traditional • Used for food and feed • Modifying agricultural waste  materials that do not have economic value by direct use, or for conversion by animals into valuable products • Undigestible carbohydrates are wrapped in large leaves (banana) and left 1-2 d for solid fermentation • Mixed inoculum of wild fungi

  4. Tempeh – food • Tempeh – Rhizopus oligosporus • Soya beans or other plant material • Uses similar to tofu

  5. Quorn mycoprotein • Fusarium graminearum A3/5 • 1964 RankHovisMcDougall (RHM)  high-protein foods from starch • Highly branched ‘colonial’ mutant CC1-1 that arose spontaneously in a glucose-limited culture of F. graminearum (now called F. venatum) • Unlike tofu, has a meat-like texture, chewiness, mouthfeel • January 1985 – marketed in England • Vegetarianism; Mad cow disease • February 2002 – marketed in USA • http://www.cce.cornell.edu/food/fsarchives/050602/quorn.html

  6. Culturing Fusarium graminearum A3/5 • Isolated from soil, UK • Liquid fermenters – stirred and cooled • Oxygen, nitrogen, waste soluble carbohydrates, and vitamins • RNA-reduction process – “debittering” improves digestibility • Current annual production: 14,000 tons • “…between chicken and mushroom in texture, with very little inherent flavor “

  7. Quorn mycoprotein  publicity • “Quorn fillets [are] made from succulent mushroom protein, coated in light crispy batter” • like mushrooms, truffles and morels • hails from the fungi family • deliver unrivaled taste, as well as an exceptional nutritional profile. • excellent source of protein and fiber • cholesterol free; low in fat, especially saturated fat

  8. Single Cell Protein technology • Toprina – animal feed – 1970s • Candida lipolytica cultivated on C15 n-alkanes • initially at Grangemouth (Scotland); later production scale in Sardinia • significant feature  hydrocarbon was completely fermented • protein content ~ 65% • production uneconomic due to cost of cooling the fermenters

  9. Soya sauce, miso, tamari • Soya bean + wheat flour + Aspergillus  Koji mold Sprinkled over toasted wheat flour Steamed soya beans Cooled Sprinkled with Aspergillus sojae

  10. Soya sauce, miso, tamari • Three days of aerobic fermentation • Cool temperature to prevent bacterial overgrowth • Transferred to barrels • Brine added to ~15% salt 18 months

  11. Soya sauce, miso, tamari Liquid – soya sauce Solid – miso and tamari Further maturation  up to several months, cool temperature

  12. Tempeh • Soybeans are boiled and dehulled • Rhizopus oligosporus grows < 24 h, creating a solid cake of hyphae/beans • Soybeans are made more digestible by lipases and proteases secreted by Rhizopus,as well as fungal components • Growth is halted (cooking, freezing) before sporulation begins (NB: oligosporus = few spores” • Traditionally, tempeh is stored wrapped in banana leaves, and eaten soon after preparation

  13. Modified forage • 2.1 x 1012 kg per year – cereal straw, sugarcane and sugar beet residue – contains nutrients, primarily as cellulose and lignins • low digestibility (40-60%) even for herbivores • generally subsistence nutrition, but leads to low growth rates, and need for feed supplements • uses naturally occurring fungi, &/or inoculated deliberately

  14. Basic Mushroom culture • Grow spawn on grains • Inoculate substrate • Mycelial growth in substrate • Fruiting, harvest, grading

  15. Commercial mushroom growing Crimini (Italian brown) • Agaricus brunescens 3-7 d

  16. Commercial mushrooms • Pleurotus ostreatus – oyster mushroom – straw, sawdust,bagasse and molasses (from sugar refining)

  17. Commercial mushrooms • Shiitake – Lentinus edodes • Inoculated into oak logs

  18. Commercial mushrooms • Enoki • Flammulina velutipes http://www.mykoweb.com/CAF/species/Flammulina_velutipes.html

  19. Commercial mushroom harvest – wild mushrooms can save the forest • Morchella, Cantharellus Value to the forest: $$, mycorrhizae, environmental monitoring

  20. Morels in truffle juice 50g 11.60€ Boletus granulatus, Tricholoma terreum, Lactarius deliciosusGuaranteed freshly picked up 200g 3.95 € Boletus edulis 200 g 6.98 € http://www.lefruitier.com/provence-shop/catalog_products_with_images.php

  21. Cheese manufacture • Fungi  flavour and texture ONLY

  22. Roquefort Sheep’s milk Penicillium roquefortii

  23. Roquefort productionwww.frencheese.co.uk • traditional cheese-making process • genuine Roquefort cheese  look for the red sheep seal on the packaging • sheep’s milk is shipped to the cheese-making facilities in 40 liter containers, rather than tanker trucks, to avoid breaking up the milk-fat on the way • milk is tested and filtered, but neither pasteurized nor homogenized • prepared with rennet for two hours • whey is drained  curds are hand-ladled into draining molds

  24. Roquefort productionwww.frencheese.co.uk • whey is drained  curds are hand-ladled into draining molds • Penicillium roqueforti culture is added (same culture used to make English Stilton) • P. roqueforti grown by leaving bread in the caves for six to eight weeks until it was consumed by the mold  crumb was then dried to produce a powder • “finished” cheeses are stored for a week and turned frequently • moved to the caves of Cambalou • salted and pierced to encourage the growth of the mold • aged in the caves at least three months

  25. Blue cheese options

  26. The story of penicillin –the contaminant that changed history • Alexander Fleming & Staphylococcus aureus • Contaminated plate showed a “zone of inhibition Original culture was Penicillium notatum

  27. Development of submerged fermenters for aerobic fungi Industrial development was moved to Illinois to protect from WWII (Chain and Florey) Original culture ‘lost’; reisolated; modified and selected P. chrysogenum and submerged culture

  28. Bacillus + penicillin Bacillus

  29. Antibiotic resistance 40,000 units total  500,000 per day typical treatment 20 million kg antibiotics / year in US; 70% used in agriculture

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