The present embodiment relates to a process for producing a grown material, and more particularly to a process for producing a grown leather-like material for an apparel, bag or multiple other such purposes, from assisted growth of multiple fungal and bacterial species on flowers and/or their extracts/parts.
BACKGROUND
Leather is a durable and flexible material manufactured by tanning animal skins and raw hides. The preservation process employed by a chemical treatment called tanning which converts the perishable skin into a non-decaying material. In the present day, a range of material, for a range of purposes is being grown or manufactured today using several starting materials. The most prominent materials especially for more prominent purposes are usually manufactured using several chemicals, minerals, ores, fossils etc. The materials have also been prepared using trees, plants and animals for several purposes and such materials are called grown materials.
The production of many materials and composites produces significant hazardous environmental effects in form of pollution that is caused by their production and processing, as well as their non-biodegradability or recalcitrance.
One such material is leather obtained from hides of animals such as goats, buffalo, etc. The material is either obtained from dead animals or the animals are grown to have them culled for such purposes. While the practice has been prevalent from ancient times, it has come under severe criticism in recent times. However, the appeal and aesthetic of leather products remain unmatched, and therefore, it has been long desired to have a leather-like material providing a leather-like appearance that can be used in bags, apparels, upholstery, footwear, and other such industries. Faux leather or synthetic leather has been developed to replace the grown leather or natural leather e.g., prestoff, made from paper pulp but which loses cohesion under wear and moisture; rexine, which is made from nitrocellulose, camphor, alcohol and pigment; however, rexine fails to maintain the aesthetic appeal of the leather; poromerics, made from polyurethane; however, it is not aesthetically appealing to sense of touch and many more substitutes, which were found prohibitive in terms of cost.
Tanning leather products are not eco-friendly, the chemicals used for tanning gives out toxic gases and effluent, which makes it a dangerous place for humans and environment as well. The modern tanning process uses loads of energy, water and chemicals. Most of the leather comes from China and India where there are no stringent animal welfare laws. Buying leather directly encourages animal killing.
Reducing use of leather or alternatives is the only solution to end the cruelty done to animals. Around 40 million animals are killed every year for their fur that are raised in small, dirty cages and treated inhumanely.
Fungi are one of the faster growing organisms having a cell wall getting extended at the tips of the hyphae. While the cell wall of a plant is made up of cellulose, the structural components of animal cells mainly include collagen, whereas fungal cell walls largely comprise Chitin, which is a hard and strong fibrous substance. A few prior art references disclose use of fungal species to grow material based on Chitin; however, the processes make use of defined media or substrates.
Further, growth of fungal species such as Pleurotus ostreatus (Oyster), Trametes versicolor (Turkey Tail), Hericium erinaceus (Lions Mane), Lentinula edodes (Shiitake), Grifola frondosa (Maitake), Ganoderma lucidum (Reishi) on floral substrate is hindered by many factors. It is believed that growing such fungal species on appropriate substrates may yield a more leather-like substance/material.
Simultaneously, there is a problem pertaining to flower waste. Flowers are universally used for several such occasions such as marriage, celebrations, funerals, religious rites etc. However, the problem pertaining to their waste has not been addressed extensively apart from their use as bio fertilizer or plant growth materials.
Summarizing all above, there remains a need for processes for obtaining leather-like material that can be as aesthetically appealing and durable as real leather by using select fungal species or species that are best suited for such purpose.
Therefore, in light of foregoing discussion, there is a need to overcome the limitations related with the traditional method.
SUMMARY OF THE INVENTION
In view of the foregoing, a process for obtaining a faux leather material is provided.
In an aspect, a process to prepare a leather-like grown material is provided. The process includes preparing (102) a Symbiotic Culture of Bacteria and Yeast (SCOBY) the SCOBY; growing SCOBY/Cellulose sheets (104) by inoculating the SCOBY in a cellulose rich media or substrates; inoculating (106) and incubating the SCOBY/ Cellulose sheets with grain spawns; and extracting mycelia sheet grown over SCOBY/ Cellulose sheet as the leather-like grown material.
The grain spawn includes any or all of fungal species/strains selected from Pleurotus ostreatus (Oyster), Trametes versicolor (Turkey Tail), Hericium erinaceus (Lions Mane), Lentinula edodes (Shiitake), Grifola frondosa (Maitake), Ganoderma lucidum (Reishi) and other basidiomycetes. The cellulose rich media may be kombucha tea and water mixture having sugar. The process further includes increasing pH of the SCOBY/ Cellulose sheets before inoculating them to grain spawns. The SCOBY/ Cellulose sheets are inoculated with the grain spawn at both ends of the SCOBY/ Cellulose sheets. The grain spawns are prepared by adding at least one fungal culture or colony to a boiling mixture of grains and any of the chemicals selected from Ca(OH)2, CaSO4, Lime or Gypsum.
In another aspect, a leather-like grown composite material including at least one SCOBY/cellulose sheet and at least one mycelia sheet grown over the SCOBY/cellulose sheet is provided. The SCOBY/cellulose sheet is SCOBY/kombucha sheet. The SCOBY/cellulose sheet is sandwiched between the mycelia sheet.

BRIEF DESCRIPTION OF DRAWING
The drawing/s mentioned herein disclose exemplary embodiments of the claimed invention. Other objects, features, and advantages of the present invention will be apparent from the following description when read with reference to the accompanying drawing.
Figure 1 illustrates a flowchart that depicts a method of producing a leather-like grown material, according to an embodiment herein.
To facilitate understanding, like reference numerals have been used, where possible to designate like elements common to the figures.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
This section is intended to provide explanation and description of various possible embodiments of the present invention. The embodiments used herein, and the various features and advantageous details thereof are explained more fully with reference to non-limiting embodiments illustrated in the accompanying drawing/s and detailed in the following description. The examples used herein are intended only to facilitate understanding of ways in which the embodiments may be practiced and to enable the person skilled in the art to practice the embodiments used herein. Also, the examples/embodiments described herein should not be construed as limiting the scope of the embodiments herein.
The source and geographical origin of the biological resources used herein is India.
As mentioned, there is a need for sustainable processes using natural substrates/resources to manufacture materials for multiple purposes. The embodiment herein overcomes the limitations of the prior art by providing an aesthetically appealing and durable as real leather by using select fungal species or species that are best suited for such purpose. The embodiment herein provides a process for producing a leather-like material or a composite leather-like material by growing one or more fungal and bacterial species on a flower substrate or flower-based substrate or media.
A common problem associated with growing fungal species on flora substrate is their inability to utilize cellulose; thereby, leading to underutilization of floral substrate or media. This problem is overcome by first growing and obtaining strains that are adapted to grow on a cellulose-rich media or substrate. In an embodiment, the cellulose rich media includes kombucha tea or other such tea leaves, or a defined cellulose-rich media. However, the process has to be adapted to grow a leather-like composite material.
Figure 1 illustrates a flowchart that depicts process 100 for producing a leather-like grown composite material, according to an embodiment herein. The process 100 includes the preparation 102 of a SCOBY (Symbiotic Culture Of Bacteria and Yeast), growing 104 SCOBY/cellulose sheets by adding SCOBY in a cellulose rich media or substrate. In an embodiment, SCOBY is added or grown in a mixture of kombucha tea and sugar to obtain SCOBY/kombucha sheets. In an embodiment, SCOBY/kombucha sheet is SCOBY/cellulose sheet. The mixture of cellulose-rich media containing SCOBY is allowed to incubate until SCOBY/cellulose sheets are obtained, which are then inoculated 106 with grain spawns and incubated until mycelia sheet grows over the SCOBY/cellulose sheets. In a preferred embodiment, where SCOBY is added to mixture of kombucha tea and sugar, the mixture is allowed to incubate until SCOBY/kombucha sheets are obtained, which are then inoculated 106 with grain spawns and incubated until mycelia sheet grows over the SCOBY/kombucha sheets.
The mycelia sheet is then extracted and used as the leather-like grown material. The process may further include steps of dehydrating the mycelia sheet in step 108 and subjecting the sheets to dyeing and drying in step 110. In an embodiment, the post-processing steps of dyeing and drying 110 the mycelia sheets, or the chemically dehydrated mycelia sheets are soaked in solutions such as Alum and heated. The sheets are then transferred to a solution containing natural dyes and soaked in them for a desired amount of time. The excess colour may then be removed by rinsing under water, which is then followed by drying in ovens to obtain a fully processed leather-like grown material according to an embodiment herein. In an embodiment, the sheets coloured sheets may be dried under sun or using hot air blowers.
In step 102, the Symbiotic Culture of Bacteria and Yeast is prepared. The symbiotic culture, SCOBY includes aerobic-gram negative Acetic Acid Bacteria (AAB) species such as Acetobacter, Gluconobacter and Komagataeibacter; aerobic-gram positive Lactic Acid Bacteria (LAB) such as Lactobacillus together with various yeasts such as Saccharomyces and Zygosaccharomyces. The growth of these species is hindered on flower or flower substrates supported media/nutrition; therefore, these strains are first grown in the mixture of cellulose rich media and sugar in step 104.
In step 104, SCOBY/Cellulose sheets are obtained. In an embodiment, SCOBY/kombucha sheet is SCOBY/cellulose sheet. In an instance, when kombucha tea is used as cellulose-rich substrate, the method step includes boiling water and soaking tea bags in the boiled water. In an embodiment, the tea bags are that of tea powder. The water is boiled, poured into a tray and tea bags are soaked into it. To this mixture, sugar is added and is allowed to cool. In an embodiment, after cooling vinegar is added to the sugar mixture. To this, SCOBY inoculum is added and allowed to incubate for a number of days at an optimal temperature. In an embodiment, the optimal temperature is 250C. In an embodiment, the incubation period is 10-20 days. At the end of the incubation period, a number of SCOBY/Kombucha sheets are obtained. In an embodiment, SCOBY/cellulose sheets may be obtained by using cellulose-rich media/substrate.
In step 106, the SCOBY/cellulose e.g., SCOBY/kombucha sheets are inoculated with grain spawns or flower substrates or a mixture thereof. The grains spawns are obtained by growing fungal species in grain media. The step includes preparation of agar culture or plates. In an embodiment, potato dextrose agar (PDA) solution is used to prepare agar plates, which are then inoculated with a fungal colony or an existing colonised agar, and the freshly prepared agar plates are thus incubated (108) to obtain fully colonized plates. In an embodiment, instead of PDA, Malt Extract Agar (MEA), Czapek Dox Agar or Wort Agar is used. The fungal strains include Pleurotus ostreatus (Oyster), Trametes versicolor (Turkey Tail), Hericium erinaceus (Lions Mane), Lentinula edodes (Shiitake), Grifola frondosa (Maitake), Ganoderma lucidum (Reishi) and other basidiomycetes.
The grain spawns are prepared by boiling the grains in water. In an embodiment, the grains are selected from list of wheat, rice, millet or any other nutritious grains. The boiled grains are mixed with 0.1 – 0.6% w/w CaCO3 and transferred to bags or jars or bottles. Alternatively, in place of CaCO3, Ca(OH)2, CaSO4, lime or gypsum is used. The bags/jars/bottles containing grain spawns are sterilized in autoclaves and cooled. The colonized agar plate’s fungal colonies are then added to the grain bag/jar/bottles and sealed, and are incubated for a number of days at room temperature. In an embodiment, the incubation period is 10-20 days. The sealed bags/jars/bottles are intermixed by applying vertical and horizontal strokers on fixed intervals such as on 4th day and 8th day. At the end of incubation period, the grain spawn is obtained.
The subsequent step of preparing a leather-like grown composite material includes treatment and inoculation of SCOBY/cellulose sheets e.g., SCOBY/kombucha sheets obtained in step 104 in grain spawns. The pH of SCOBY sheets is around 2 i.e. acidic. The pH is therefore increased by addition of Calcium Hydroxide gradually. These SCOBY/kombucha or SCOBY/cellulose sheets are then inoculated with the colonized grain spawn on either ends, which are then incubated for desired number of days until a growth of mycelia is seen on the SCOBY/cellulose sheets. The mycelia sheet so obtained is extracted, which may be used as faux leather or leather-like material. In an embodiment, the pH of the SCOBY/cellulose sheets is increased by addition of NaOH, NH4OH or Lime.
In an embodiment, the sheets so obtained may have to be subjected to certain post-processing steps before they may be employed for several purposes. In an embodiment the post-processing steps includes plasticization (108), where the raw leather-like grown material sheets are processed with dehydrating chemicals.
In an embodiment, the chemical is ethanol which is done to remove water content. However, in order to retain the flexibility of the sheets (since the water has been removed), glycerol or other such chemicals may be added.
In an embodiment the post-processing steps also includes dyeing and drying (110) the raw sheets, or the chemically dehydrated sheets are soaked in solutions such as Alum and heated. The sheets are then transferred to solution containing natural dyes and soaked in them for a desired amount of time. The excess colour may then be removed by rinsing under water, which is then followed by drying in ovens to obtain a fully processed leather-like grown material according to an embodiment herein.
In an aspect, a leather-like grown composite material is provided. The material includes SCOBY/cellulose sheet and mycelia. In an embodiment, the material includes SCOBY/kombucha sheet and mycelia. In an embodiment, SCOBY sheets are sandwiched between mycelia. In a preferred embodiment, SCOBY sheet intermingle with or form cross links with mycelia sheet.
In an aspect, a leather-like grown composite material having SCOBY/Cellulose sheet obtained by a process including growing SCOBY/cellulose sheets in a cellulose-rich media,
EXAMPLES:
EXAMPLE 1: Preparation of SCOBY/Kombucha Sheets
One liter water was boiled, poured into a tray and tea bags were soaked into it followed by mixing of 100 gm sugar into the boiling water and the solution was allowed to cool down to room temperature. After cooling, 100 ml vinegar was mixed into the solution. Finally, 2-4 pieces of SCOBY culture 2X2 inches in size were added to a tray and it was incubated for 15 days at 25°C. At the end of this cycle, a SCOBY sheet occupying the whole tray was obtained.
EXAMPLE 2: Preparation of Agar Culture Plates
A Potato Dextrose Agar (PDA) solution was prepared by addition of 3.9 gm of PDA in 100 ml water followed by heat sterilization at 121 0C in an autoclave. The PDA solution was then poured in 90 mm diameter petri-plates and was cooled down inside Laminar Flow Hood for 40-45 minutes. The process of cooling down automatically solidifies the solution to form gel in the plate. A colonized agar piece of size 5mm x 5mm obtained from an old culture plate was introduced inside the fresh prepared plate as inoculum. Inoculated plates were incubated at 27 °C for 8 days in BOD (Biological Oxygen Demand) incubator for complete colonization of mycelium. The fully colonized plates are stored at -20°C for future use.
EXAMPLE 3: Preparation of grain spawn
Grain spawns were prepared by boiling the wheat grains in water for approximately 30 minutes. The mixture was continuously stirred at 10 rpm. The boiled grains were mixed with 0.5% w/w CaCO3 (Calcium carbonate) and transferred to PPE filter bags with 0.2-micron fabric filters attached over them. The bags prepared were sterilized at 1210C and 15 psi pressure for 90 minutes in an autoclave. The autoclaved grains were allowed to cool down to room temperature inside a laminar flow hood. Approximately 30-40% of well colonized agar plate prepared was added to the grain bag. The PPE filter bags with grains mixture were sealed. The sealed bags were then incubated at room temperature for 12-14 days. The sealed bags were intermixed by applying vertical and horizontal stroke shaking on the 4th and 8th day of incubation in order to obtain uniform colonization. The prepared grain spawn was stored at -4 °C for later use.
EXAMPLE 4: Treatment and Inoculation of SCOBY sheets
The pH value of the SCOBY sheet was around 2, i.e. too acidic. The pH of the sheets was increased by addition of Ca(OH)2 (0.1%, 0.5% and 1%.).The treated SCOBY sheets were inoculated with spawn on both ends. These trays then incubated at 25 °C for 25 days. The mycelia growth over these SCOBY sheets was observed in 25 days. The mycelia sheet grown over this kombucha sheet is extracted and was further used for inoculation in other methods or directly as leather-like grown material sheets.

As will be readily apparent to those skilled in the art, the present embodiment may easily be produced in other specific forms without departing from its essential characteristics. The present embodiment are, therefore, to be considered as merely illustrative and not restrictive, the scope being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.

We claim:
1. A process to prepare a leather-like grown material comprising:
preparing (102) a Symbiotic Culture of Bacteria and Yeast (SCOBY) the SCOBY;
growing SCOBY/cellulose sheets (104) by inoculating the SCOBY in a cellulose-rich media or substrate;
inoculating (106) and incubating the SCOBY/Cellulose sheets with grain spawns; and
extracting mycelia sheet grown over SCOBY/cellulose sheet as the leather-like grown composite material.
2. The process as claimed in claim 1, wherein the cellulose-rich substrate is kombucha tea .
3. A process to prepare a leather-like grown material comprising:
preparing (102) a Symbiotic Culture of Bacteria and Yeast (SCOBY) the SCOBY;
growing SCOBY/kombucha sheets (104) by inoculating the SCOBY in a kombucha tea water mixture;
inoculating (106) and incubating the SCOBY/Kombucha sheets with grain spawns; and
extracting mycelia sheet grown over SCOBY/kombucha sheet as the leather-like grown material.
4. The process as claimed in claim 1 or 3, wherein spawn of any or all of fungal species/strains selected from Pleurotus ostreatus (Oyster), Trametes versicolor (Turkey Tail), Hericium erinaceus (Lions Mane), Lentinula edodes (Shiitake), Grifola frondosa (Maitake), and Ganoderma lucidum (Reishi) and other basidiomycetes.
5. The process as claimed in claim 1 or 3, further comprises increasing pH of the SCOBY/kombucha sheets or SCOBY/cellulose sheets before inoculating them to grain spawns.
6. The process as claimed in claim 1 or 3, wherein the SCOBY/kombucha sheets or SCOBY/cellulose sheets are inoculated with the grain spawn at both ends of the SCOBY/Kombucha sheets or SCOBY/cellulose sheets.
7. The process as claimed in claim 1, wherein the grain spawns are prepared by adding at least one fungal culture or colony to a boiling mixture of grains and any of the chemicals selected from Ca(OH)2, CaSO4, Lime or Gypsum.
8. A leather-like grown composite material comprising at least one SCOBY/cellulose sheet and at least one mycelia sheet grown over the SCOBY/cellulose sheet.
9. The material as claimed in claim 8, wherein the SCOBY/cellulose sheet is SCOBY/kombucha sheet.
10. The material as claimed in claim 8, wherein the SCOBY/cellulose sheet is sandwiched between the mycelia sheet.