The present embodiment relates to a process for producing a grown composite material, and more particularly to a process for producing a grown leather-like composite material for manufacturing an apparel, bag or multiple other such articles, from assisted growth of multiple fungal species, especially medicinal fungal species, on flowers and/or their extracts/parts.
BACKGROUND
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 the 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.
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.
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 biofertilizer or plant growth materials.
Therefore, in light of foregoing discussion, there remains a need for obtaining leather-like material that can be as aesthetically appealing and durable as real leather.
SUMMARY OF THE INVENTION
In view of foregoing, a leatherlike grown material and a process to obtain such a material is provided.
In an aspect, a process for obtaining leatherlike grown material is provided. The process includes inoculating (104) desired fungal species/strains in a pre-scale up media having flower or flower substrates or flower extracts or any part of flower to obtain at least one sheet of the leatherlike grown material; and inoculating (106) at least one sheet of the leatherlike grown material in a scaleup media having flower or flower substrates or flower extracts or any part of flower to obtain a plurality of sheets of the raw leatherlike grown material.
The process further includes dehydrating (108) the plurality of sheets of the raw leatherlike grown material to obtain dehydrated sheets of the leatherlike grown material. The process further includes treating simultaneously or subsequently to dehydrating (108), the treating (110) sheets of the leatherlike grown material are treated with glycerols, fats, oils or mixtures thereof.
The sheets of the raw leatherlike grown material are dehydrated by treating the sheets with Ethanol. The pre-scaleup media comprises flowers or flower extracts or any parts of flower or mixture thereof, glucose, magnesium sulphate, potassium dihydrogen phosphate and potassium hydrogen phosphate, yeast extract and peptone. The scaleup media comprises flowers or flower parts or flower extracts or mixture thereof, wheat flour, sugar, magnesium sulphate, potassium dihydrogen phosphate and soya bean. The process further includes dyeing the sheets of the leatherlike grown material by heating them in alum. The sheet of the leatherlike grown material is inoculated in the scaleup media in a bioreactor. The sheet of the leatherlike grown material is transferred to scaleup media either sideways or in a distributed form. The process further includes drying the sheets of the leatherlike grown material.
BRIEF DESCRIPTION OF DRAWING
The drawing 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 the process for producing a leatherlike grown material by growing fungal strains/species on a flower substrate or flower-based substrate or media, 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 herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples 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.
The terms “fungal strain” and/or “fungal species” and/or “fungi” refer to a fungus or multiple fungi and are used interchangeably.
As mentioned, there remains need of sustainable processes using natural substrates/resources to manufacture materials for multiple purposes. The embodiment herein provides a process for producing a leatherlike material or a composite leatherlike material by growing one or more fungal species on a flower substrate or flower-based substrate or media. In an embodiment, medicinal fungal species are grown on flower or flower-based substrate.
Figure 1 illustrates a flowchart that depicts a process (100) for producing a leatherlike grown material, by growing fungal strains/species on a flower substrate or flower-based substrate or media, according to an embodiment herein.
The process (100) includes growing (102) desired fungal strains/species in agar culture plates or broth solutions by inoculating a number of agar culture plates or both solutions with desired fungal strains/species, growing at least one sheet of leather-like material (104) by inoculating a number of desired fungal species/strains colonies obtained from step (102) in a pre-scale up media that contains flowers/flower substrates/flower parts/flower extracts, and then obtaining (106) the leatherlike material of an embodiment herein by inoculating and incubating the sheets obtained from step (104) in a -scale up media that contains flowers/flower substrates/flower parts/flower extracts. The grown leather-like material is obtained as sheets according to an embodiment herein in step (106). The process of preparing the grown leather-like material of an embodiment herein further includes a process of plasticization (108) of the sheets obtained, which are then subjected to step of colouring (dyeing) and drying (110).
The process of obtaining the grown leather-like material is initiated with growing desired fungal species/strains in agar culture plates or broth solutions that are suitable for growth of desired fungal species in step (102). 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 colonized agar, and the freshly prepared agar plates are thus incubated to obtain fully colonized plates. Alternatively, Malt Extract Agar (MEA), Czapek Dox Agar or Wort Agar may be used in place of PDA Another method of obtaining or preparing an inoculum of desired fungal species/strains is by employing broth. In an embodiment, Potato Dextrose Broth (PDB) is used. In a preferred embodiment, the fully colonized agar agar pieces from PDA plates are mixed in PDB and incubated to obtain inoculum. Alternatively, Malt Extract Pure, Barley Extract, Wheat or Rice Extracts or Ragi Extracts may be used in place of PDB.
In step (104), at least one leatherlike material sheet is grown by inoculating a pre-scaleup media with the inoculum having desired fungal strains/species as obtained in step (102). The pre-scaleup media includes flowers, glucose, magnesium sulphate, potassium dihydrogen phosphate and potassium hydrogen phosphate, yeast extract and peptone. In an embodiment, the pre-scaleup media includes 5%-10% w/v flowers, 3%-8% w/v glucose, 0.05%-0.10% w/v Magnesium sulphate (MgSO4.7H2O), 0.046%-0.092% w/v potassium di-hydrogen phosphate (KH2PO4), 0.1%-0.2% w/v potassium hydrogen phosphate (K2HPO4), 0.2%-0.4% w/v yeast extract, and 0.2 %-0.4% w/v peptone. In an embodiment, yeast extract is replaced with beef extract. The ingredients are mixed in deionized water having pH ranging from 4 to 6 to obtain a first media solution. The pH may be adjusted by adding acids or bases such as acetic acid-6 by adding acid, such as acetic acid. The first media solution thus obtained, is sterilized. In a preferred embodiment, the sterilization is done by heat at 121°C and 15 psi pressure for 20 mins in an autoclave. The sterilized media is allowed to cool and then is poured in a tray. The tray may be of any stable and inert material such as polycarbonate. The inoculant is then poured into the pre-scaleup media in the trays. The trays are then sealed using filter bags and are left to incubate for a few days at optimal temperature, e.g., 30 0C. In an embodiment, the incubation is done for 7-15 days. In an embodiment, the incubation is done until at least two required sheets of the leatherlike grown material of embodiment herein is obtained.
In an embodiment, the incubation for required number of days is done until at least two required sheets of the leather like grown material.
In the subsequent step, i.e. step (106), multiple sheets of leatherlike material, from the 1-2 sheets obtained from step (104), are obtained by inoculating the sheets from (104) in a scaleup media. The scale up media contains flowers, wheat flour, sugar, magnesium sulphate, potassium dihydrogen phosphate and soya bean. In an embodiment, the scaleup media includes 1-5% w/v flowers, 0.5-4% w/v wheat or corn or rice or millet flour, 0.5 - 4% w/v any carbon source like sugar cane juice, liquid starch , 0.01-0.06% w/v Magnesium sulphate (MgSO4), 0.02-0.07% w/v potassium dihydrogen phosphate (KH2PO4), 0.1 – 3% w/v of any nitrogen source like yeast extract, beef extract or soya bean flour. These ingredients are mixed in deionized water whose pH is maintained from 3 -6 to obtain a second media solution. The pH may be adjusted by adding acids or bases. In an embodiment, acetic acid is used to maintain pH in the required range. The second media solution is then sterilized at 121°C and 15 psi pressure for 20 mins in an autoclave. It may be apparent to person skilled in the art to use other means to sterilize media. The second media is then cooled and poured on a surface such as trays. In an embodiment, the trays are made of inert and stable material such as polycarbonate. The two leatherlike sheets, obtained from step (104), are then inoculated in the second media solution or the scaleup media solution. The two leatherlike material sheets are transferred to this freshly prepared second media solution or scaleup media tray either by sideway or distributed way. In an embodiment, whereas in sideway, the sheets from pre scale media are thick, flipped upside down and placed sideways inside large size tray as it is in an intact manner. In an embodiment, whereas in distributed way, the sheets from pre scale media are thin thus they are broken into small pieces and then distributed in the scaleup media tray. The scaleup media trays inoculated with leatherlike grown material from step (104) are then sealed and incubated at 30 °C for a number of days. In an embodiment, the incubation is done for 12-20 days. In an embodiment the sheets are flipped twice, separated by an interval of 5-8 days for obtaining thicker and uniform leatherlike grown material. In an embodiment, raw leatherlike material sheets are obtained at the end of 15 days of incubation.
In an embodiment, the fungal species/strains and their cultures are grown in conical flasks at different stages of growth like in pre-scaleup media, scaleup media with higher volumes, before finally transferring and finally the well grown culture transferred to required size of the tray to grow to size of the tray. Alternatively, bioreactors with high volume size may also be used to scale up the process obtaining high volumes of leatherlike grown material sheets.
Further, post-processing processes are carried out. The step (108) and (110) are the two post-processing steps. In the post-processing step (108), the plasticization of the leatherlike material sheets is performed. In an embodiment, the plasticization of the leatherlike material sheets is done using dehydrating chemicals. The plasticization refers to the process of making a material elastic and flexible. In present embodiment, the plasticization of the raw leatherlike grown material sheets from step (106) is done using ethanol, which removes water or moisture from the sheets. Simultaneously, in order to retain the flexibility of the sheets after dehydration or removal of water/moisture, any of the chemicals that may impart flexibility to the dehydrated material may be added. In an embodiment, the dehydrated sheets of the leatherlike grown material is treated with glycerol, fats and oil to retain their flexibility.
The process of dyeing and drying is carried out at step (110) after the plasticization. In step (110), the plasticized sheets are introduced into 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 be removed by rinsing under water. This is then followed by drying in ovens to obtain a fully processed leatherlike grown material according to an embodiment herein. In an embodiment, the drying may be done under sun or hot air blowers or any other means meant for drying.

EXAMPLES:
EXAMPLE 1: Preparation of agar culture plates
A Potato Dextrose Agar (PDA) or Malt Extract Agar (MEA) solution was prepared by addition of appropriate amounts of nutrient in 100 ml water followed by heat sterilization at 121 0C in an autoclave. The PDA or MEA solution was then poured in 90 mm diameter petri-plates and was cooled down inside laminar air flow hood for 40-45 minutes. The process of cooling down automatically solidifies the solution to form potato dextrose agar 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 colonized plates were stored at -20°C for future use.
EXAMPLE 2: Preparation of inoculum
Potato Dextrose Broth (PDB) or Malt Extract (ME) solution was prepared by addition of appropriate amounts of nutrient in 200 ml water followed by heat sterilization at 121° C in an autoclave. PDB or ME solution was poured in conical flask and allowed to cool down inside laminar air flow hood for 40-45 minutes. PDB solution was mixed with few 1cm x 1cm sized pieces of fully colonized PDA culture plates. The mixture was then incubated inside a shaker incubator at 26-30°C for 2 weeks.
EXAMPLE 3: Preparation of pre-scale up media
Pre scale up media was prepared with volume 500 ml containing 5% w/v flowers along with appropriate salt combination and nutritional media. The afore-mentioned ingredients are mixed as per the given composition in deionized water. The pH of the solution was maintained between 5-6 by addition of acid or base. The media solution was then heat sterilized at 121°C and 15 psi pressure for 20 mins in an autoclave. The media was then allowed to cool down inside laminar air flow hood for 40-45 minutes. The prepared media was poured in a plastic tray of size 13X9 inches. The ready inoculum prepared in earlier step was poured in the tray and mixed with the freshly prepared and sterilized media inside the laminar air flow hood itself. The whole assembly was sealed in a PPE filter bag. These trays are then incubated at 30 °C for 10 days.
EXAMPLE 4: Preparation of scale up media
Scale up media was prepared with volume 1.5 L containing 5% w/v flowers supported with readily available raw nutritional support along with appropriate salt combination. The above-mentioned ingredients are mixed as per the given composition in deionized water. The pH of the above solution was maintained at 5 by addition of acetic acid. The media solution was then heat sterilized at 121°C and 15 psi pressure for 20 mins in an autoclave. The media was than allowed to cool down inside laminar air flow hood for 40-45 minutes. The prepared media was then poured in polycarbonate tray of size 18X13 inches. Two ready sheets grown in pre scale up media as mentioned in earlier step are transferred to this freshly prepared media tray either by sideway or distributed way. The whole assembly was sealed in a PPE filter bag with 5-micron fabric filter attached over them. These trays are then incubated at 30 °C. Two flips of the sheets, separated by time interval of 8 days are carried out for obtaining thicker and uniform sheets. At the end of the 15 days incubation cycle, the leatherlike grown material sheets are obtained in their raw form.
EXAMPLE 5: Plasticization
The raw sheets were processed with Ethanol gradient to remove the water content from them, followed by treatment with Glycerol, fats and oils.

EXAMPLE 6: Dyeing and Drying
The sheets are soaked into a mordent solution such as alum and heated till 100 °C for 15 minutes. Sheets are then transferred to solution containing natural dyes and soaked in them for 2 hours at room temperature. After removing from colour solutions, the sheets are rinsed under tap water to remove excess colour and dried in oven at temperature in the range of 80-90°C for 5-6 hours to obtain final leatherlike 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 for obtaining leatherlike grown material comprising:
inoculating (104) desired fungal species/strains in a pre-scale up media having flower or flower substrates or flower extracts or any part of flower to obtain at least one sheet of the leatherlike grown material; and
inoculating (106) at least one sheet of the leatherlike grown material in a scaleup media having flower or flower substrates or flower extracts or any part of flower to obtain a plurality of sheets of the raw leatherlike grown material.
2. The process as claimed in claim 1 further comprises dehydrating (108) the plurality of sheets of the raw leatherlike grown material to obtained dehydrated sheets of the leatherlike grown material.
3. The process as claimed in claim 2 further comprises treating simultaneously or subsequently to dehydrating (108), the treating (110) sheets of the leatherlike grown material are treated with glycerols, fats, oils or mixtures thereof.
4. The process as claimed in claim 2, wherein the plurality of sheets of the raw leatherlike grown material are dehydrated by treating the sheets with Ethanol.
5. The process as claimed in claim 1, wherein the pre-scaleup media comprises flowers or flower extracts or any parts of flower or mixture thereof, glucose, magnesium sulphate, potassium dihydrogen phosphate and potassium hydrogen phosphate, yeast extract and peptone.
6. The process as claimed in claim 1, wherein the scaleup media comprises flowers or flower parts or flower extracts or mixture thereof, wheat flour, sugar, magnesium sulphate, potassium dihydrogen phosphate and soya bean.
7. The process as claimed in claim 2 or 3 further comprising dyeing the sheets of the leatherlike grown material by heating them in alum.
8. The process as claimed in claim 1, wherein the at least one sheet of the leatherlike grown material is inoculated in the scaleup media in a bioreactor.
9. The process as claimed in claim 1, wherein the at least one sheet of the leatherlike grown material is transferred to scaleup media either sideways or in a distributed form.
10. The process as claimed in claim 7 further comprises drying the sheets of the leatherlike grown material.