The project focused on the validation and scaling-up of a complete production process of ingredients from 4 algae, using cascading biorefinery approach that includes pretreatment, fractionation and conversion technologies, to be used in food, feed and cosmetic products and resulted in a range of replacement ingredients sourced from microalgae (Spirulina platensis and Nannochloropsis sp.) and macroalgae (Ulva ohnoi and Saccharina latissima). In this sense, IGV optimized, cultivated (up to pilot scale) and harvested microalgae Spirulina platensis and Nannochloropsis sp. biomass, produced in indoor closed photobioreactors, employing Glass photobioreactors and MUTL ®, the ¨mesh-ultra-thin-layer-technology¨. This optimization process involved parameters control, such as: nutrients, light, CO2, temperature, thus reaching an increase of yield of ingredients of interest.
CTAQUA focused on the cultivation of the macroalge (Ulva ohnoi), in laboratory-based photobioreactors, then upscaled in open ponds, and cultivated in cages, focusing on the seeding, harvesting and invasive species protection.
Meanwhile, AT-SEA Nova, optimized a patented advanced textile cultivation of Saccharina latissima, in European seas, focusing on seeding technology, timing of seeding and harvesting, together with confronting with climatic influences. Innovative approach, throughout the replacement of the conventional 2D rope, and offering a greater production yield through a larger cultivation surface.
VITO, CNTA and Feyecon researchers have developed and upscaled ¨zero waste¨ extraction protocols, tailored for each of the 4 algae strains of the project, aiming for the extraction of useful products on a “cascading” basis, so that each refining stage produces new, useful products and nothing is discarded. Reagents and chemicals used have also been selected for maximum sustainability. This resulting in a range of replacement ingredients sourced from algae, including proteins, phycocyanin, fatty acids, carbohydrates, carotenoids, lipids and sugar enriched extracts.
BIOPOLIS, CNTA and AITEX have identified added value in the obtained algal products, applicable to the envisaged industries in the project, including anti-microbial effect, protection against UV damage,fat reduction and antioxidant properties.
These compounds are employed in the development of functional food, feed and cosmetic products, with the aim of replacing conventional ingredients, which may be imported or generate contamination, with high added value algal ingredients. In addition, VLCI determined the compatibility solubility properties of these ingredients via the Hansen Solubility Parameter workflow, to efficiently find matching ingredients and formulate them, with highest efficacy.
For example, the Soria Natural has replaced soy protein with algae protein for veggie burgers, CPCFEED suggested swapping fish plasma with algal proteins and included microalgal biomass in animal piglet feed, DIBAQ and CTAQUA experimented the replacement of protein, and polysaccharide, in fish diets, and developed antioxidants and HENKEL tested other ingredients from algae, such as lipids or sugars to be used in cosmetic products, as marine carries, algae caviar and personal care products.
LCA and sLCA assessment was performed, by TABU for the validation of the feasibility of this complete production process of ingredients of algae into industrial products, considering the definition of the profile of each product and societal acceptance of this new sustainable ingredients source.
