H2020 FUNGUSCHAIN Project: Valorization of agricultural mushroom waste to obtain high-value products

To achieve the first main objective, we originally proposed the extraction of all valuable active molecules in a sequential cascade process for the isolation of target biomolecules (5 types: antioxidants, antimicrobials, lipids, proteins and polysaccharides) obtained from fungal residues in a cascade approach to valorize all secondary components and achieve their comprehensive utilization.

An integrated cascade process has been established that matches the objectives and intended intermediate products. Since an initial version of the cascade found economics and, to a lesser extent, environmental impact (energy consumption) unfavorable for a significant portion of the cascade, a modified version has been scaled up and proven industrially viable. New cascade processes focused on cost-effectiveness generate relatively rudimentary intermediate products with favorable environmental and safety profiles, ensuring scalability and local circular deployment. Previous initial cascade steps (high-value protein-enriched mushroom powders, flavoring extract, and subsequent cascade intermediates) have favorable commercial prospects, particularly in food and cosmetic products, as well as in specialty plastics, particularly biodegradable mulch and protective films with circular agricultural applications.

In total, a 76% to 95% valorization of mushroom agricultural waste can be achieved, depending on the specific biorefinery configuration. Furthermore, biogas production and composting can be used to utilize the eventual waste. To meet the second objective, end-users were required to validate the extracted biomolecules by introducing them into selected products within their own commercial portfolio to demonstrate functionality and improvements over current non-biotechnology-based counterparts. The final products focused primarily on food additives, protein-enhanced powders, functional foods, industrial films, and cosmetic products. The DEMO lines developed during the project enabled the production of the selected high-value-added additives and final products for initial exploitation by the project partners. A technical and economic feasibility study was conducted for the investments required for the construction and commissioning of pilot plants and modifications of current industrial lines. Using the integrated and flexible efforts of all partners, the complex waterfall process and the challenge of generating profitable products have been addressed in an agile and proactive manner.

This has led to a range of innovative product lines, which contribute to meeting this objective. Process and product selection and investments by Monaghan Mushrooms were undertaken to generate a commercially attractive operational biorefinery, enabling the operational integrated production of multiple high-value bio-based products. FUNGUSCHAIN demonstrated that the extraction of valuable biomolecules prior to lower-value applications provides attractive options for the valorization of valuable natural products. This is often best achieved with relatively fresh biomass present on a local and relatively small scale, promoting innovative bio-based startups in rural areas. However, there are several problems in the natural products market directly related to their immaturity. Insufficient production in certain cases can greatly limit market growth, while underutilization leads to the accumulation of waste.

This requires tailor-made solutions, such as those developed by FUNGUSCHAIN in the context of Objective 3. The reintroduction of agricultural waste into a circular economy through the use of novel methods to identify valuable ingredients and environmentally friendly extraction procedures that are easily scalable and deployed by SMEs and local industries characterizes FUNGUSCHAIN's approach. There is enormous potential for market penetration, as the number of potential applications for biomaterials obtained from agricultural waste is vast.

We therefore set out to provide an incentive to change this situation and promote innovation and development in rural areas, also aiming to: (i) improve citizens' health; ii) increase the productivity of agricultural income and promote industrial processes; iii) improve environmental sustainability and safety to ensure the acceptance of new bio-based products.

We have demonstrated the production of different types of biodegradable and recyclable bioplastics with different applications in a circular economy. We have improved environmental impact by avoiding chemical extraction and reducing energy requirements. We have designed and applied a novel human cell-based rapid safety assessment tool for complex mixtures of undefined bio-based compounds, which revealed no safety concerns for the cascade fractions and products tested. We have designed cost-effective products with zero waste streams and innovative product options where cascade waste can be used for biogas and compost production, achieving full circularity. To promote local entrepreneurship and further rural development in the north of Ireland, Monaghan has not only invested in the advanced biorefinery but has also made a very significant investment in a novel innovation to further support this ambition. This center will be located adjacent to the biorefinery.