Engineering Strategies for Fungal Cell Disruption in Biotechnological Applications

Fungal cell disruption plays a critical role in unlocking a wide range of high-value intracellular products such as lipids, proteins, pigments, and bioactive compounds. However, lysing fungal cells is far more challenging than breaking bacterial or algal cells due to their robust and highly structured cell walls. These biological barriers demand a tailored and strategic approach depending on the fungal species, cell morphology, and downstream processing requirements. This review explores the various mechanical and non-mechanical methods used to disrupt fungal cells, beyond outlining the core principles behind each method, the engineering and process factors that influence their performance are emphasized. A comparative analysis is provided, focusing on key parameters like disruption efficiency, scalability, cost-effectiveness, and environmental impact. The review also sheds light on emerging hybrid and integrated approaches, the role of pre-treatment or co-treatment strategies, and the potential for greener and more sustainable alternatives aligned with circular bioeconomy goals. Ultimately, this review aims to serve as a guide for researchers, bioprocess engineers, and industry professionals seeking to optimize fungal bioproduct extraction in a way that is not only technically sound but also economically viable and environmentally responsible, paving the way for more efficient, scalable, and sustainable fungal-based biomanufacturing.