Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) is a biobased and biodegradable polymer. This polymer is considered promising, but it is also rather expensive. The objective of this study was to compound PHBV with three different organic fillers considered waste: human hair waste (HHW), sawdust (SD) and chitin from shrimp shells. Thus, the cost of the biopolymer is reduced, and, at the same time, waste materials are valorised into something useful. The composites prepared were characterised by differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), tensile strength and scanning electron micrograph (SEM). Tests showed that chitin and HHW did not have a reinforcing effect on tensile strength while the SD increased the tensile strength at break to a certain degree. The biodegradation of the different composites was evaluated by a soil burial test for five months. The gravimetric test showed that neat PHBV was moderately degraded (about 5% weight loss) while reinforcing the polymer with organic waste clearly improved the biodegradation. The strongest biodegradation was achieved when the biopolymer was compounded with HHW (35% weight loss). The strong biodegradation of HHW was further demonstrated by characterisation by Fourier-transform infrared spectroscopy (FTIR) and solid-state nuclear magnetic resonance (NMR). Characterisation by SEM showed that the surfaces of the biodegraded samples were eroded.

Fungal mycelium is emerging as a source for sustainable bio-based materials. Fungal biomass of Aspergillus oryzae was prepared by cultivation on bread waste hydrolysate to valorize this abundant food waste. Chitin-glucan-rich alkali-insoluble material (AIM) was isolated from fungal biomass, formed into hydrogels, and wet spun into monofilaments. AIM in the form of fungal microfibers containing 0.09 g polymer of glucosamine (GlcN)/g AIM was subjected to freeze–thaw and deacetylation treatments to increase the amount of GlcN. The GlcN fraction was 0.19 and 0.34 g polymer of GlcN/g AIM, for AIM subjected to deacetylation (AIM-DAC) and freeze–thaw cycles and deacetylation (AIM-FRTH-DAC), respectively. The increased GlcN fraction enabled the formation of hydrogels via the protonation of amino groups after the addition of lactic acid. Morphological differences in the hydrogels included aggregation of the fungal microfibers in the AIM-DAC hydrogel, whereas the microfibers in the AIM-FRTH-DAC hydrogel had a porous and interconnected network. Rheological assessment revealed shear thinning behavior and gel properties of the produced hydrogels. Wet spinning of the hydrogels resulted in monofilaments with tensile strengths of up to 70 MPa and 12 % elongation at break. This demonstrates promising avenues for biomaterial development from fungal cell walls containing chitin-glucan via food waste valorization.

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. 

The Current study aimed at valorizing carrot pomace (CP), an abundant waste from the juice industry. A water-soluble fraction of CP was separated from solid fraction of CP (SFCP) and employed as feedstock for producing fungal biomass (FB) in bench-scale bioreactors. FB combined with SFCP were used to develop mycelium-based papers (MBP) using the wet-laid method. The potential and capacity of FB, SFCP and MBP to remove dye (methylene blue) from wastewater was then investigated. The maximum achieved dye removal was 92% when using a mixture of SFCP and FB in their suspended forms. The MBP with the lowest density (549 kg/m3) reached 83% dye elimination. The findings of this study support the valorization of carrot pomace, through environmentally benign processes, to mycelium-based papers with potential application in wastewater treatment.

Citrus waste has been used as a source of bioplastics for research in different ways. Because the juice industry produces significant amounts of residue each year, it would be advantageous to use the byproducts in the creation of new materials. Researchers have long explored eco-friendly methods to convert citrus and other organic waste into polymers for producing biodegradable films. The goal of this study is to create biofilms from orange waste (OW) and ginger waste (GW) using an ultrafine grinder and study the films’ properties. Since pectin has the ability to gel, and because cellulosic fibers are strong, citrus waste has been studied for its potential to produce biofilms. After being washed, dried, and milled, orange and ginger waste was shaped into films using a casting process. Tensile testing was used to determine the mechanical properties of biofilms, while dynamic mechanical thermal analysis (DMTA), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC) were used to determine their thermal properties. As the number of grinding cycles increased, the suspension’s viscosity increased from 29 mPa.s to 57 mPa.s for OW and from 217 mPa.s to 376 mPa.s for GW, while the particle size in the suspension significantly decreased. For OW and GW films, the highest tensile strength was 17 MPa and 15 MPa, respectively. The maximum strain obtained among all films was 4.8%. All the tested films were stable up to 150 °C, and maximum degradation occured after 300 °C.

Carrot pomace (CP) which is generated in a large volume in the juice production process, is rich in cellulose, hemicellulose, sugars, pectin, and minerals. However, in many previous investigations, only cellulose was purified and utilized while other components of CP were discarded as waste. Here, CP was valorized into fungal biomass and cellulose with the aim of utilizing all the CP components. Enzymatic pretreatments were applied to solubilize the digestible fraction of CP including hemicellulose, pectin, sucrose, and other sugars for fungal cultivation, while cellulose remained intact in the solid fraction. The dissolved fraction was utilized as a substrate for the cultivation of an edible fungus (Rhizopus delemar). Fungal cultivation was performed in shake flasks and bench-scale bioreactors. The highest fungal biomass concentration was obtained after pretreatment with invertase (5.01 g/L) after 72 h of cultivation (36 and 42% higher than the concentrations obtained after hemicellulase and pectinase treatments, respectively). Invertase pretreatment resulted in the hydrolysis of sucrose, which could then be taken up by the fungus. Carbohydrate analysis showed 28–33% glucan, 4.1–4.9% other polysaccharides, 0.01% lignin, and 2.7–7% ash in the CP residues after enzymatic pretreatment. Fourier transform infrared spectroscopy and thermogravimetric analysis also confirmed the presence of cellulose in this fraction. The obtained fungal biomass has a high potential for food or feed applications, or as a raw material for the development of biomaterials. Cellulose could be purified from the solid fraction and used for applications such as biobased-textiles or membranes for wastewater treatment, where pure cellulose is needed.

A fungal biorefinery is presented to valorize food waste to fungal monofilaments with tunable properties for different textile applications. Rhizopus delemar is successfully grown on bread waste and the fibrous cell wall is isolated. A spinnable hydrogel is produced from cell wall by protonation of amino groups of chitosan followed by homogenization and concentration. Fungal hydrogel is wet spun to form fungal monofilaments which underwent post-treatments to tune the properties. The highest tensile strength of untreated monofilaments is 65 MPa (and 4% elongation at break). The overall highest tensile strength of 140.9 MPa, is achieved by water post-treatment. Moreover, post-treatment with 3% glycerol resulted in the highest elongation % at break, i.e., 14%. The uniformity of the monofilaments also increased after the post-treatments. The obtained monofilaments are compared with commercial fibers using Ashby's plots and potential applications are discussed. The wet spun monofilaments are located in the category of natural fibers in Ashby's plots. After water and glycerol treatments, the properties shifted toward metals and elastomers, respectively. The compatibility of the monofilaments with human skin cells is supported by a biocompatibility assay. These findings demonstrate fungal monofilaments with tunable properties fitting a wide range of sustainable textiles applications. 

Agricultural residues are constantly increasing with increased farming processes, and improper disposal is detrimental to the environment. Majority of these waste residues are rich in lignocellulose, which makes them suitable substrate for bacterial fermentation in the production of valueadded products. In this study, bacterial cellulose (BC), a purer and better form of cellulose, was produced by two Komagataeibacter sp. isolated from rotten banana and kombucha drink using corncob (CC) and sugarcane bagasse (SCB) enzymatic hydrolyzate, under different fermentation conditions, that is, static, continuous, and intermittent agitation. The physicochemical and mechanical properties of the BC films were then investigated by Fourier Transformed Infrared Spectroscopy (FTIR), Thermogravimetry analysis, Field Emission Scanning Electron Microscopy (FESEM), and Dynamic mechanical analysis. Agitation gave a higher BC yield, with Komagataeibacter sp. CCUG73629 producing BC from CC with a dry weight of 1.6 g/L and 1.4 g/L under continuous and intermittent agitation, respectively, compared with that of 0.9 g/L in HS medium. While BC yield of dry weight up to 1.2 g/L was obtained from SCB by Komagataeibacter sp. CCUG73630 under continuous agitation compared to that of 0.3 g/L in HS medium. FTIR analysis showed BC bands associated with cellulose I, with high thermal stability. The FE-SEM analysis showed that BC fibers were highly ordered and densely packed. Although the BC produced by both strains showed similar physicochemical and morphological properties, the BC produced by the Komagataeibacter sp. CCUG73630 in CC under intermittent agitation had the best modulus of elasticity, 10.8 GPa and tensile strength, 70.9 MPa. [GRAPHICS]

Purified fungal chitosan and crustacean chitosan were wet spun by using adipic and lactic acids as solvent. The lowest viscosity at which fiber formation was possible was 0.5 Pa·s; below this value, aggregates from low molecular weight fungal chitosan (32 kDa) formed, which could not be collected and dried. Fiber formation was achieved with high molecular weight fungal (400 kDa) and shrimp (406.7 kDa) chitosans as well as low molecular weight shrimp chitosan (50–190 kDa). Fibers made of high molecular weight chitosans with adipic acid as the solvent generally exhibited higher tensile strength; the highest observed tensile strength and Young’s modulus were 308.0 ± 18.4 MPa and 22.7 ± 4.0 GPa, respectively. SEM images indicated the formation of cylindrical chitosan fibers. The survival (viability) of human skin fibroblasts in presence of different fibers was measured using tetrazolium-based colorimetric assay and results confirmed that chitosan fibers have better biocompatibility than common conventional sutures, regardless of the chitosan and acid type. Accordingly, chitosan fibers from fungal and shrimp sources serve as good candidates for application as sutures.

The fungus Rhizopus delemar was grown on bread waste in a submerged cultivation process and wet-laid into films. Alkali or enzyme treatments were used to isolate the fungal cell wall. A heat treatment was also applied to deactivate biological activity of the fungus. Homogenization of fungal biomass was done by an iterative ultrafine grinding process. Finally, the biomass was cast into films by a wet-laid process. Ultrafine grinding resulted in densification of the films. Fungal films showed tensile strengths of up to 18.1 MPa, a Young's modulus of 2.3 GPa and a strain at break of 1.4%. Highest tensile strength was achieved using alkali treatment, with SEM analysis showing a dense and highly organized structure. In contrast, less organized structures were obtained using enzymatic or heat treatments. A cell viability assay and fluorescent staining confirmed the biocompatibility of the films. A promising route for food waste valorization to sustainable fungal wet-laid films was established. © 2022 The Authors