Strain development, bioprocess optimization, and food-structure design for sustainable mycoprotein production from...

Rising global protein demand, the environmental constraints of conventional animal agriculture, and the imperative for sustainable food systems have intensified interest in alternative protein sources. Mycoprotein-edible biomass derived from filamentous fungi cultivated by aerobic submerged fermentation-offers a scalable platform for producing complete protein with favorable amino acid profiles, dietary fiber, and bioactive compounds. Despite commercial successes, persistent challenges in protein yield, sensory quality, digestibility, and process economics necessitate continued innovation across the entire value chain. This review proposes a strain-process-structure-function (SPSF) framework that integrates upstream strain selection and engineering, fermentation-process optimization, continuous-production robustness, downstream processing, and food-structure design into a unified, product-oriented perspective for sustainable mycoprotein production. Optimized culture conditions and low-cost feedstocks are improving the scalability and economic viability of mycoprotein manufacturing. Continuous fermentation, online monitoring, soft sensors, and intelligent process control are further strengthening process stability and industrial feasibility. In parallel, strain improvement strategies have enabled targeted enhancements in biomass formation, protein accumulation, amino acid biosynthesis, cell-wall architecture, and stress tolerance; rational rewiring of carbon and nitrogen metabolism, proteostasis networks, morphological determinants, and cell-wall biosynthetic pathways offers further opportunities to improve protein yield, digestibility, and fermentation robustness. Downstream processing and structure-driven formulation, in turn, govern protein accessibility, texture, sensory quality, and consumer acceptance. Together, the SPSF framework developed here shifts mycoprotein research from the isolated optimization of protein yield, digestibility, or texture toward coordinated, multi-objective design across the full value chain. The convergence-positions mycoprotein as a compelling next-generation protein source that can contribute to global food security.