Several innovative strategies have been developed and implemented to increase efficiency and reduce the cost of the final microalgae products, namely: i) selection of new Chlorella vulgaris strains with improved protein content and organoleptic characteristics, ii) more efficient mixotrophic and heterotrophic growth for Galdiera sulphuraria and Chlorella vulgaris, and iii) reduction of the cost and increase of the production efficiency, like the CO2 absorption prototype (Direct Air Capture), the valorisation of side streams such as insect frass and recycled water for microalgae cultivation, and the installation of an “off-the-grid” photo-bioreactor.
Solar drying was the most promising technology for the production of single-cell proteins to operate in batch mode while pulsed combustion drying, and agitated thin film drying were the best ones when considering continuous process. Concerning protein isolates, Electrostatic Spray Drying showed improved drying performances compared to conventional spray drying.
The extraction of protein isolates has been performed on Tetraselmis chui and Spirulina up to industrial levels. The extraction strategies resulted to be very strain-dependent and also influenced by the physiological state of the culture.
The Spirulina and T. chui protein extraction process generates side-products characterized by interesting nutritional value, and techno-functional and digestibility properties which make them suitable for food and feed applications.
Seven innovative food products were reformulated with microalgae ingredients and scaled up at the industrial level to be used in consumer tests. Consumer acceptance depended on the combination of product and microalgae strain considered.
Five feed formulations for poultry, piglets, catfish, carp, and shrimps were successfully developed by replacing up to half the protein content from soya with microalgae. These feeds were successively produced at industrial scale and employed for animal trials, which indicated that microalgae could compete with soy-based diets in terms of growth performance and meat quality parameters.
The social and environmental opportunities and constraints of the microalgae value chain were identified through different survey activities. Results showed that consumers are currently not very familiar with food products added with microalgae and the majority have not tried nor tasted them before.
Results from market analysis suggested that legislation needs to be revised to simplify the marketing of microalgae and guarantee the stability of imported strains, as well as scaling up and lowering production costs.
A preliminary regulatory assessment to identify EU specific requirements for the authorization of novel foods was conducted.
A decision support tool, integrating data from LCA/LCC analysis, was developed to optimize the processing routes of the microalgae-based proteins for food and feed applications. .
Consistent high-quality posting on social media, implementation of product samplings, collaboration with industry, pursuit of certifications, continuous R&D efforts, and scientific dissemination have been identified as key exploitation routes.
Targeted strategies to disseminate and communicate the objectives and outcomes of the project were developed through the project (social media, 20 scientific publications, webinars, press releases, etc..). ProFuture results were presented at a final public conference in Brussels.
