Novel and sustainable biotechnological approaches for astaxanthin and ketocarotenoids production

Project Information

ASTEASIER

Grant agreement ID: 101099476

DOI

10.3030/101099476

Project closed

EC signature date 26 October 2022

Start date 1 January 2023

End date 31 December 2024

Funded under

• The European Innovation Council (EIC)

Total cost

€ 1 982 688,00

EU contribution

€ 1 982 688,00

Coordinated by

UNIVERSITA DEGLI STUDI DI VERONA
Italy

Periodic Reporting for period 2 - ASTEASIER (Novel and sustainable biotechnological approaches for astaxanthin and ketocarotenoids production)

Reporting period: 2024-01-01 to 2024-12-31

Summary of the context and overall objectives of the project

Astaxanthin (AX) is a red pigment, a carotenoid, mostly used in fish diet that is responsible for pink/orange pigmentation of salmons of shrimps. More than 90% of the AX market is taken by its synthetic form, obtained as a by-product of crude oil refining. However, the natural form, produced by some specific eukaryotic microorganisms, provides a much stronger antioxidant power compared to the synthetic one, increasing the immune response to pathogens and viruses, which makes it an ideal ingredient also for nutraceuticals and cosmetics. The preferential use of synthetic AX in aquaculture is mainly due to the price point of synthetic AX, ranging from 1,000 – 2,000 €/kg instead of up to 15,000 €/kg of natural AX. Synthetic AX is thus only used as a pigment, as fish colour is perceived by the customers as one of the most important quality indicators, while the true power of natural AX in farmed fish is still unexploited. Starting from the results of the “SOLENALGAE” ERC-StG project and two subsequent ERC Proof of Concept projects, the ASTEASIER project focuses on the development of novel methods to produce and extract AX enriched with Omega 3 and other nutrients from microalgae, which has proven to decrease the production cost in the range of synthetic AX. The aim of the project was to take the technology to TRL6 and spin off a company that aims to become a leader in engineering microalgae to produce and sell natural products such as AX and other valuable components for human and animal nutrition and wellness. The main goal of the ASTEASIER project is to validate at the industrial level the technology previously developed by UNIVR regarding novel biotechnological processes for astaxanthin (AX) production.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project aimed to validate ASTEASIER technology at the industrial level, focusing on both AX production and its use in aquafeed.
In WP1, UNIVR’s microalgal strains were successfully cultivated at an industrial scale in 1,000 and 5,000-liter photobioreactors at A4F. Results showed that ASTEASIER technology could produce AX at an industrial scale, with a maximum productivity of 114 mg AX m-2 day-1. A 1,000-liter pilot plant was installed at UNIVR, reaching 125 mg AX m-2 day-1 using the engineered Synechococcus sp. PCC 11901 BC strain.
WP2 involved a techno-economic analysis by A4F, which modeled different AX pricing scenarios, demonstrating that the natural AX herein developed can be competitive with synthetic AX. The LCA analysis, set from "cradle-to-gate," examined the environmental impact from raw material extraction to microalgae powder production. The carbon footprint ranged from 1.40 to 7.96 kgCO2eq/kgDW, while the water footprint ranged from 7.36 to 11.04 m3/kgDW. The lowest environmental impacts were seen in Synechococcus BC production, with the LCA showing Global Warming Potential values comparable to or lower than existing benchmarks.
In WP3, ASTEASIER products were tested for use in aquafeed with BioMar. Feed production completed at M13, and trials with Atlantic salmon began at M14 and finished at M18. Results showed that fish fed Synechococcus and synthetic pigment had higher redness and astaxanthin levels compared to other treatments. While synthetic AX incorporated better into the flesh, similar pigmentation was achieved with Synechococcus BC biomass.
WP4 focused on the Tech to Market Transition. Day One evaluated profitability, identifying AX market segments and potential customers. The IPR strategy was strengthened, leading to international extension for algae biomass and aquafeed production. A B2B sales Business Model canvas was developed, targeting feed, nutraceutical, and cosmetics industries. Economic and financial projections for ASTEASIER srl were completed, with the new company launched on M19. ASTEASIER srl negotiated exclusive licensing with UNIVR, raised private investment, and is set to enter the market in 2025.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The main results obtained at the end of the project are:
1) The demonstration that novel platforms for the production of natural AX from microalgae can be obtained by the cultivation of ASTEASIER strains in industrial facilities. These results represent a change in the paradigm for AX production: up to now, natural AX in the market is produced from bacteria in a carbon-emitting process or from the costly cultivation of two phases (a green and a red phase) of the green alga Haematococcus pluvialis. Here, natural AX can be produced in a single cultivation phase assimilating CO2 and adopting the microalgal strains at the base of ASTEASIER technology.
2) Novel aquafeed formulation was obtained by BioMar substituting synthetic AX with AX-enriched biomass produced by microalgae. This formulation provides not only AX but also other important nutritional compounds such as omega-3 and proteins.
3) AX produced by the novel microalgal strains developed in the ASTEASIER project could substitute synthetic AX in feed trials performed by BIOMAR in industrially relevant environments. This result was specifically obtained in the case of AX produced in the Synechococcus BC strain, the most performing strain in terms of AX productivity
4) ASTEASIER products were characterized by favorable LCA parameters, such as carbon and water footprint compared to the state-of-the-art
5) An industrial process was developed allowing to separately extract AX, omega-3 and phycocyanin from the microalgal biomass produced
A business model and business plan for tech-to-market activities were defined, leading to the launch of a start-up called ASTEASIER srl, which will take care of the next steps to enter the market (see below). The start-up, launched in July 2024, was already able to raise funds from private investors, and it is now in the fundraising stage to enter the market in 2025 and enlarge its production capacity.
The main achievements needed by the ASTEASIER technology to reach the market are the industrial validation of the extraction process (required to enter the nutraceutical market), the definition and achievement of the certification required to enter into the feed market, and obtaining the necessary funds to set up a production plant that can fulfill the demand of our potential customers, such as Biomar.

Demo unit (1000L scale) installed by A4F at UNIVR

A gallery from Asteasier successes during the pitching competitions