Scale-Up of Duddingtonia flagrans Chlamydospores Production from Laboratory to Pilot-Scale Using a Solid-State Fermentation System.

The fungus Duddingtonia flagrans is a biological control tool to reduce infective larvae of gastrointestinal nematode in pastures. To create a commercially available bioproduct based on a nematophagous fungus, an efficient mass production process should be developed that is able to guarantee a good predatory capacity and satisfactory production rates. In this work, solid-state fermentation (SSF) parameters were investigated to produce D. flagrans at pilot-scale. The results showed that the relative humidity was a critical factor to increase productivity and to reduce fermentation time. The best production conditions using a tray bioreactor were a relative humidity in the room at 90% for 2 days, and inoculation by sprinkling. The fermentation process was composed of 7 days under submerged fermentation to produce the inoculum and 7 more days of SSF in a tray bioreactor. The productivity reached was 4.96 × 10 chlamydospores g of dry substrate day, which is the highest productivity reported to date. The predatory capacity of the chlamydospores produced using this process was 91%. Also, a statistical control process analysis was applied, finding that the process presents stability in the biological activity, yield, and final moisture content of the substrate between batches. Finally, the operational expenses (OPEX) based on the use of the heating and humidification system were estimated, given a final cost of 0.20 USD g of the fermented substrate.