Container for Mushrooms and Method for the Manufacture Thereof

The invention relates to a container for the storage, transport, and/or sale of mushrooms, the use thereof, and a method for the manufacture thereof.

Surplus manure has become one of the biggest environmental problems. The harmful substances, ammonia, phosphates, and nitrates in manure are an important cause of the acidification and dying of woodlands. The minerals contaminate the soil as well as groundwater and surface water; production of drinking water comes under pressure. The ammonia formed causes acidification of the air. To prevent overuse of manure, in many countries the production and processing of manure is regulated by strict manure legislation.

In the past, large investments have already been made in manure processing for example by starting up manure factories which process the surplus manure mechanically to dry fertilizer granules. Dry fertilizer granules can be spread on the field easily without odor nuisance. In certain cultures manure is used in the form of dried boards for plastering walls or as fuel. On the other hand fresh manure, such as fresh horse manure and chicken manure, is commonly used in the growing of mushrooms and for early crops of vegetables, among other things, by both growers and hobbyists.

At the start of the growing of mushrooms, compost suitable for growing mushrooms is inoculated with mycelium. For growing white mushrooms, for example, compost is preferably made up of wheat straw (carbon source and structure), horse manure (for nutrients), and/or chicken manure (or slurry, as nitrogen source). Other mushrooms may require other types of manure or growing media for their optimal growth. After harvesting the mushrooms, a second, third, fourth, fifth, and/or sixth round of growth of mushrooms may be achieved on the same compost. With increasing number of rounds of growth, the production and quality of the mushrooms decrease, and introduction of pests and diseases increases; the compost is exhausted and so is removed. After this complete growing procedure, we thus end up with a large amount of residual substrate (mushroom compost). Disposal and decontamination after growing also involve costs.

In today's large-scale or commercial mushroom growing concerns, after harvesting, the mushrooms are sorted and weighed in packaging so as to minimize handling, which may damage the mushrooms. Harvested mushrooms have the drawback that after a few days they have a brown coloration and develop spore formation. Keeping mushrooms fresh, particularly during transport and/or even brief storage, is thus a great problem. Temperature and humidity fluctuations within the packaging have a considerable effect on the quality of the stored product.

The classic white mushrooms or champignons have already been sold since the middle of last century in the typical blue trays. The blue sheen of the plastic tray makes the mushrooms look more appealing. The blue trays are usually recyclable, but the blue color is left behind as a contaminant in the recycled material. There is a trend toward replacing the trays with transparent plastic or with cardboard trays with a water-repellent coating. Both alternatives are easier to recycle but there is still a further increase in the mountain of waste.

Cellulose fibers, necessary as raw material for the production of cardboard trays, can be obtained from wood by cooking wood chips in a chemical solution (sodium sulfide), so that the wood falls apart into loose fibers (chemical pulp; separation of lignin and cellulose is obtained) or using a grinding process (mechanical pulp). Alternatively, old paper may be dissolved in water (recycled fibers). Possible contaminants, such as staples, adhesive tape and printing ink, can be removed from the pulp, a mixture of wood fibers and liquid; fiber pulp can be bleached. After a process of sieving, pressing and drying, most of the liquid has been removed from the formed paper. Each sieve makes a thin layer of paper; several layers can be pressed together with formation of (massive) cardboard. Optionally, a layer with moisture-repelling properties may be applied on the upper side and/or underside; for example a layer containing a polyethylene (PE) coating. Using these processes, we are left with paper waste in the recycling circuit.

Recyclable paper waste is also used for producing egg boxes, among other things. After adding water (70-80 wt %), the paper waste (20-30 wt %) is processed to pulp; pulp is poured into molds; sides are pressed on; and then dried in a drying system. Egg boxes can be used several times, and can be reintroduced into a recycling system. We are again left with paper waste in the recycling circuit.

To summarize, the present invention offers a solution for the aforementioned problems by providing at least one of the following aspects: 1/ direct residual substrate processing, 2/ indirect processing of surplus manure, 3/ easier production of storage trays, 4/ cheaper production of storage trays, 5/ greater product freshness of mushrooms, 6/ longer product shelf life of mushrooms, 7/ storage conditions of mushrooms easier to control and optimize; 8/ less food wastage; and/or 9/ (better and quicker) production of environmentally friendly and compostable storage trays.

The inventors found, unexpectedly, that residual substrate, derived from the growing of mushrooms on a substrate, is an ideal raw material for the production of a container for the storage, transport and/or sale of mushrooms. The inventors also found, unexpectedly, that by using the container of the invention, mushrooms can be obtained with long-term quality of a high standard. The inventors found further, unexpectedly, that through production of the container of the invention, storage trays could be formed that can be composted better and quicker. In general, the present invention offers a better solution for the compostable processing of waste in combination with a less expensive approach for guaranteeing improved product freshness of mushrooms.

The invention aims to employ manure further, directly (as manure and/or a component of compost) or indirectly (as a component of the substrate and/or residual substrate), as raw material for manufacturing a container for the storage, transport and/or sale of mushrooms. Here, the manure is not used for growing mushrooms, but for their storage and handling. Thus, a more inactive role is now ascribed to the manure/substrate (by using spent residual substrate). Up to now, mushrooms have been stored in plastic trays or trays made of cardboard or paper. The present inventors have discovered, unexpectedly, that the residual substrate derived from the growing of mushrooms on a substrate is an ideal source for producing pulp, which may then be used to obtain the container of the present invention. Through the digesting or composting of fresh manure, the carbon content decreases and the relative nitrogen content increases, so that the fertilizing value increases; the fiber-like carbon-containing constituents are digested. Prior to the present invention, the processing of manure was not applied in direct combination with storage of food, and was considered unacceptable. Now, manure processing is subject to very strict rules. It should also be noted that manure, substrate and residual substrate usually also carry germs (pathogens). The present inventors have developed a method in which containers can be produced that can be used in a food-safe manner, without the need for additional testing.

The partly or completely digested manure can be used together with wood or straw for growing mushrooms. Wood and straw are of course composites consisting of long, branched cellulose, hemicellulose, and lignin fibers that anchor one another, so that they are difficultly degradable. Through the growth of the fungus, this complex rigid network is converted to a more flexible, compressible mass. During growth, first the mycelium develops in the substrate, followed by the formation of the mushroom fruiting bodies. The underground hyphae are microscopically thin filaments with a diameter from 2 to 100 micrometers. For the production of mushrooms, the mycelium usually only decomposes a portion (25%) of the organic matter in the compost. After growth of the mushrooms, the residual substrate thus consists of (partly) digested substrate permeated by a network of hyphae. The residual substrate has physical properties which are, unexpectedly, optimal for the production of pulp and formation of the container of the present invention. Fungus-fermented substrate is not used in the production of the containers of the prior art. Compared to paper pulp, the residual substrate contains shorter (hemi) cellulose and lignin fibers and an extra network of hyphae. The hyphae are divided into compartments by septa (internal walls); these give the hyphae rigidity and prevent large-scale loss of cytoplasm if a break occurs in the dividing wall. During mixing, heating and/or cooking, the hyphae are partly disrupted. Through the resultant pressure from cooking, the cell walls of the remaining plant cells and mycelium cells will partly explode; fibers become softer but are not fermented as a result of this action. The inventors have discovered, unexpectedly, that on processing the residual substrate, a superior elastic raw material is obtained, which after processing and drying results in a sturdy container.

The present inventors have also discovered that the container produced on the basis of the residual substrate not only is sturdy, but possesses extra unexpected optimal properties such as increased permeability and absorption of air (e.g. CO) and moisture (e.g. water). Mushrooms are aerobic organisms that show a preference for growing on an airy substrate; therefore sometimes a mushroom growing layer is also used, which is highly permeable to water. The hyphae themselves also form a network in which extra spaces are present; during drying, these spaces are formed further and/or enlarged. On drying, these result in tiny air pockets and/or air spaces; also called intra-spaces. The inventors have discovered, unexpectedly, that on processing the residual substrate, an elastic raw material is obtained, which after processing and drying leads to a sturdy, yet light and porous container.

Owing to the sturdy structure of the container, it is possible for the manufacturer of the container to transport the containers in a compact arrangement in which they are inserted in one another. Additional structures may be applied to simplify the storage and assembly of the containers and for separating them from one another. Owing to the light structure, transport of the unused and used containers is easier, more compact and thus also cheaper. Because the raw material for pulp processing is more flexible and/or more elastic, the pulp is easier to press and/or dry. This results in lower labor costs and energy consumption.

As stated above, until now mushrooms have been stored in plastic trays or cardboard boxes with a water-repellent coating. Through temperature fluctuations during storage, transport and/or sale of the packaging, condensation may form on the underside of the lid and sides of the tray, which may have an adverse effect on the quality of the mushrooms. Because the metabolism is still active in stored mushrooms, extra moisture and COmay also be released. The porous property of the container makes it possible for the extra moisture and CO, present in a closed interior space of the container, to be channeled via the intra-spaces present in the container wall, to the exterior space of the container wall. Moreover, dry air present in the exterior spaces of the container may pass via the intra-spaces of the container wall to the interior space. There is thus an equilibrium between the exterior and interior spaces of the container; this all takes place by passive transfer or diffusion of air and/or moisture through the intra-spaces of the container wall.

The container of the present invention has increased air circulation, so that storage of mushrooms (or harvested fruit and/or vegetables) takes place optimally. Moreover, the container of the present invention has optimal moisture absorption capacity, so that formation of condensation is reduced and/or even eliminated completely. Storage of the mushrooms thus takes place in an ideal environment; taste and appearance of the mushrooms remain good for longer. Furthermore, the storage of the mushrooms in the container may be influenced further on the basis of external factors. For example, the containers, filled with mushrooms, may be brought into an artificial environment in which components that may have an effect on the mushrooms are present. Air or vapors that these components contain may be carried via the intra-spaces from the exterior space to the interior space of the container and may affect the mushrooms. For example, by incubation with maturation-inhibiting factors, the maturation of the mushrooms may be delayed.

Since storage of the mushrooms can take place optimally, storage and transport can take a longer time. The entire procedure is thus more controllable and less expensive. Fewer “overripe” mushrooms have to be thrown away; the associated costs therefore do not have to be factored into the price.

Through the entire procedure, there is a clear decrease in the mountain of waste: more specifically of surplus manure (with additional phosphate and nitrate soil pollutants), the residual substrate, old vegetable compositions such as straw and wood, food waste and the storage trays that are produced. Through fungal fermentation, smaller carbon-containing and other complex fibers are formed, which are more usable by the compost organisms. Because the container of the present invention consists entirely of natural elements, it is thus fully recyclable and degradable in nature. In contrast to the containers of the prior art, the basic structure of the container of the present invention does not have any plastic, or contaminating elements that may be present in used paper (e.g. bleaches, ink). The use of contaminating and/or nonbiodegradable elements may also be minimized or even kept absent.

The invention comprises a method for manufacturing a container for the storage, transport and/or sale of mushrooms, said method preferably comprising one or more of the steps of, more preferably comprising all the steps of:

The invention also comprises, in one embodiment, a method as described above, in which before step a), it further comprises the following steps:

The invention also comprises, in one embodiment, a method as described above, in which the mushrooms are selected from the group comprising for example white mushroom, chestnut mushroom, shiitake, wood blewit, nameko, parasol mushroom, horse mushroom, beech mushroom, chanterelle mushroom, enoli, morel, oyster mushroom, pied de mouton, pom pom blanc, portabella, trompette de la mort; preferably selected from thegroup; preferably the white mushroom or the chestnut mushroom.

The invention also comprises, in one embodiment, a method as described above, in which the mushrooms, from which the residual substrate is collected, are of the same Class, Order, Family, Genus, and/or Species as the mushrooms that are stored, transported and/or sold in the container, or in which the mushrooms, from which the residual substrate is collected, are not of the same Class, Order, Family, Genus, and/or Species as the mushrooms that are stored, transported and/or sold in the container; preferably, in which the mushrooms, from which the residual substrate is collected, are of the same Class, Order, Family, Genus, and/or Species as the mushrooms that are stored, transported and/or sold in the container.

The invention also comprises, in one embodiment, a method as described above, in which the substrate comprises a compost layer and optionally a mushroom growing layer on top of the compost layer.

The invention also comprises, in one embodiment, a method as described above, in which the compost layer comprises slurry and/or solid manure.

The invention also comprises, in one embodiment, a method as described above, in which the compost layer comprises straw, hay, and/or wood (chips). The invention also comprises, in one embodiment, a method as described above, in which the substrate comprises cellulose, lignin and/or hemicellulose.

The invention also comprises, in one embodiment, a method as described above, in which in step c) the residual substrate is mixed with an additional pulp, preferably a pulp based on paper.

The invention also comprises, in one embodiment, a method as described above, in which the transfer mold comprises a round, oval, square, rectangular, polygonal, multiplex, hexagonal, octagonal shape, or combinations thereof.

The invention also comprises, in one embodiment, a method as described above, in which the transfer mold comprises a perimeter of about 10-200 cm and a height of about 1-20 cm.

The invention also comprises a container manufactured by a method as described above, preferably wherein the container contains mushrooms.

The invention also comprises the use of the container as described above, for the storage, transport and/or sale of mushrooms.

The invention also comprises the use of a residual substrate comprising mushroom-fermented substrate, compost and/or manure for manufacturing a container for the storage, transport and/or sale of mushrooms by a method as described above.

The invention also comprises, in one embodiment, the use as described above, in which the fermented substrate, the compost and/or manure comprises fermented cellulose, lignin and/or hemicellulose.

The invention also comprises a method for the storage, transport and/or sale of mushrooms, said method comprising the steps of:

The reference numbers refer to the following stated parts of the container:

As used hereinafter, the singular forms “a”, “an” and “the” comprise both the singular and the plural unless the context is clearly otherwise.

The terms “comprise”, “comprises” as used hereinafter are synonymous with “inclusive”, “include” or “contain, “contains” and are inclusive or open and do not exclude additional, unnamed members, elements or method steps. The terms “comprise”, “comprises” include the terms “contain”, “refers to”, “is intended”, and vice versa.

The enumeration of numerical values using ranges of figures comprises all values and fractions in this range, as well as the stated end points. Stated values also comprise values after the decimal point such as: x.1, x.2, x.3, x.4, x.5, x.6, x.7, x.8, x.9, x.x1, x.x2, x.x3, x.x4, x.x5, x.x6, x.x7, x.x8, x.x9, x.xx1, x.xx2, x.xx3, x.xx4, x.xx5, x.xx6, x.xx7, x.xx8, x.xx9. The term “measurable value” referring to a measurable value such as a parameter, a quantity, and so on, is intended to include variations of +10% or less, preferably +5% or less, more preferably +1% or less, and even more preferably +0.1% or less, of and from the specified value, insofar as the variations are applicable for functioning in the disclosed invention.

Unless defined otherwise, all terms made known in the invention, including technical and scientific terms, have the meaning as usually understood by a person skilled in the art. For further guidance, definitions are included for further explanation of terms that are used in the description of the invention.gives a schematic representation of a possible embodiment of the invention with reference to the most frequently used terms.

The invention comprises a method for manufacturing a container for the storage, transport and/or sale of mushrooms, said method preferably comprising one or more of the steps of, more preferably comprising all the steps of:

The term “container” also comprises the terms “packaging”, “box”, “storage box”, “dish”, “container”, “bin”, “tray”, “basket”, or “punnet”. According to one embodiment of the invention, the container may be used not only for the storage, transport and/or sale of mushrooms, but also for collecting and handling vegetables and fruit, typically for small berries that are susceptible to bruising, perishing, and crushing, and which therefore are best stored in small rigid containers.

The term “mushroom” also comprises the terms “champignon” and “fungus”.

The “storage, transport and/or sale” may be both large-scale and small-scale, may have a commercial or personal character, and/or may be carried out by growers or hobbyists.

The term “die” also comprises the terms “mold”, “casting mold” and “form”. This is a hollow or spherical model in the contra-shape (negative) of the desired product. The raw material for the product to be made is injected, poured or drawn into the mold in the pourable and/or liquid state (heated if necessary). The process is also called “molding”, “casting” or “forming”. Then (if necessary after cooling) the mold is removed and we are left with the product. A hollow mold may also be used when the technique makes it possible to apply the product as a thin layer on the mold.

The term “mixing” also comprises the terms “knead”, “stir”, “blend”, “cut”, “grind”, “fine grinding”. The elements are brought together thereby. Preferably, during mixing the elements may be cut into finer particles in such a way that the pulp obtained becomes more homogeneous in structure. Obtaining a fine (r) pulp is not necessary; coarse structures of certain elements may still be visible in the pulp. Mixing may also be used further, for example during cooking of the mass.

The invention also comprises, in one embodiment, a method, as described above, in which the mushrooms are selected from the group comprising for example white mushroom, chestnut mushroom, shiitake, wood blewit, nameko, parasol mushroom, horse mushroom, beech mushroom, chanterelle mushroom, enoli, morel, oyster mushroom, pied de mouton, pom pom blanc, portabella, trompette de la mort; preferably selected from thegroup; preferably the white mushroom or the chestnut mushroom.

To date, some 3000 fungus species have been identified, but the total number of species that exist is not known. The invention describes a container that may be used for the storage, transport and/or sale of each type of mushroom; for example for the storage, transport and/or sale of edible, inedible, gilled mushrooms,mushrooms, straight, slanting or upright growing mushrooms. Inedible mushrooms may for example be used at low dosage in medicine.

According to one embodiment of the invention, the mushrooms from which the residual substrate is collected may be of the same Class, Order, Family, Genus, and/or Species as the mushrooms that are stored, transported and/or sold in the container, or the mushrooms from which the residual substrate is collected may not be of the same Class, Order, Family, Genus, and/or Species as the mushrooms that are stored, transported and/or sold in the container. Preferably, the mushrooms from which the residual substrate is collected are of the same Class, Order, Family, Genus, and/or Species as the mushrooms that are stored, transported and/or sold in the container. On the one hand the mushrooms from which the residual substrate is collected and the mushrooms that are stored, transported and/or sold in the container may be of the same Class. On the other hand, the mushrooms from which the residual substrate is collected and the mushrooms that are stored, transported and/or sold in the container may be of the same Order. On the other hand, the mushrooms from which the residual substrate is collected and the mushrooms that are stored, transported and/or sold in the container may belong to the same Family. On the other hand, the mushrooms from which the residual substrate is collected and the mushrooms that are stored, transported and/or sold in the container may belong to the same Genus. On the other hand, the mushrooms from which the residual substrate is collected and the mushrooms that are stored, transported and/or sold in the container may be of the same Species.

The invention also comprises, in one embodiment, a method as described above, in which in step d) the residual substrate is cooked at a temperature of 80-100° C. and/or for a period of 5-60 minutes. For example, the residual substrate may be cooked at a temperature from 85 to 95° C., or for example at a temperature of 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100° C.; preferably of 85, 90, 95 or 100° C. For example the residual substrate may be cooked for a period of 10-50 minutes, or of 20-40 minutes, or for example for a period of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60 minutes, preferably of 30, 40, 50 or 60 minutes. Cooking may also take place under pressure or in conditions in which sterilization of the residual substrate can take place more quickly. Undesirable and/or harmful organisms can be killed during this step. Conditions may thus vary depending on which organisms we wish to eliminate. A person skilled in the art is able to adjust these conditions.

After cooking, the residual substrate may be cooled slowly in the mold. Alternatively the temperature may be kept constant at certain moments; active cooling may also be applied. The cooling and drying of the transfer mold may take place within or outside the mold. Finally, a transfer mold is obtained that comprises an ambient temperature equal to the temperature of the surroundings.