ZEST is finding new ways to produce protein by using fungi to turn agricultural by-products into valuable ingredients. During the first stage of the project, the consortium has achieved substantial advances in eco-friendly and innovative approaches to creating sustainable proteins for use in food, pet nutrition, and beyond.
To start, ZEST scientists carefully selected different types of fungi and paired them with various agricultural sidestreams e.g. beet pulp that would otherwise go to waste. By initially running small-scale experiments, the project is identifying which fungi and materials work best together to create protein efficiently and for industrial implementation. This matching not only helps ensure healthy, high-quality protein production, but also supports a more circular food system by reducing waste.
A big part of ZEST’s success comes from its focus on technology. The project is building and exploring new bioreactor designs, especially addressing mass-transfer, asepticity, energy efficiency and process simplicity. These bioreactors are designed to be flexible both in the context of hardware and automation software, so to ensure their compatibility with different kinds of fermentation materials and adapt to the needs of industrial production. Early experiments have already provided valuable knowledge on how to prevent issues like biomass adhesion and ensure higher oxygen mass transfer rates at elevated viscosities.
Digital tools and artificial intelligence also play a key role in ZEST’s approach. The project is creating a digital platform to collect and analyze data from its experiments and processes in real time. This helps scientists and engineers quickly spot opportunities for improvement, react to potential problems, and continuously optimize how proteins are made. With advanced modeling and digital control systems, ZEST can bring together information from the lab and the factory floor, making the whole process smarter and more reliable.
Downstream, the project is exploring new, green ways to extract and refine the protein produced by the fungi, using methods that save energy and water, and maximize the value of every batch. Early work by ZEST teams has shown promise in creating protein-rich ingredients and identifying natural compounds, like chitin, that can be used in foods, pet nutrition, and cosmetics.
Although some tasks have experienced minor delays, mainly due to the time needed to optimize early fermentation steps, the project is making steady progress. Initial product development is already underway using lab-scale batches, and further safety, quality, and sustainability assessments are being prepared as bigger quantities become available.
By combining sustainable biotechnology, advanced engineering, and digital innovation, including the use of artificial intelligence, ZEST is demonstrating how fungi biomass, produced through novel fermentation technologies, can become a promising new source of protein from agricultural residues. These advancements open up more climate-friendly and efficient alternatives for protein production, supporting healthier diets, greener industries, and a sustainable future for all.
