Revolutionizing Eco-Friendly Leather Production: A Freeze-Thaw and Liquid Fermentation Approach with Fungal Mycelium

The environmental impact and resource demands of traditional leather manufacturing have driven the search for sustainable alternatives. Fungal mycelium leather, recognised for its eco-friendly and renewable characteristics, has emerged as a promising option. This study established a cyclic freeze-thaw dehydration protocol for preparing mycelial leather using <i>Ganoderma</i> mycelium produced through liquid fermentation. By precisely controlling the fermentation parameters (pH 5.5, 150 rpm agitation, 28 °C), the liquid fermentation process ensures uniform mycelial growth, which is critical for subsequent structural enhancement during freeze-thaw cycles. After three freeze-thaw cycles were performed at -15 °C, uniformly distributed ice crystals facilitated effective water removal, achieving a minimum moisture content of 47.6%. The optimized freeze-thaw process produced membranes with a tensile strength of 6.22 MPa and elongation at break of 18.92%, demonstrating high mechanical performance. The freeze-thaw process was demonstrated to enhance structural integrity and mechanical properties while offering reduced energy consumption compared to conventional dehydration methods. This research provides a theoretical foundation and technical guidance for optimising fungal mycelium leather production and contributes to the development of sustainable bio-based materials for industrial applications.