Improved fucoxanthin and docosahexaenoic acid productivities of a sorted self-settling Tisochrysis lutea phenotype at pilot scale

Current advances in microalgae-based fucoxanthin production and downstream processes

Fucoxanthin, a marine carotenoid primarily found in brown algae and microalgae, offers significant health benefits, including antioxidant, anti-obesity, and anti-cancer effects. While brown algae remain the dominant commercial source, microalgae such as Phaeodactylum tricornutum are emerging as promising candidates for large-scale, sustainable fucoxanthin production. This review explores advancements in fucoxanthin biosynthesis, focusing on cultivation methods, extraction techniques, and genetic engineering strategies. Different cultivation systems - including autotrophic, heterotrophic, and mixotrophic approaches - have been assessed for their biomass yield, cost-effectiveness, and scalability, together with a quantitative meta-analysis to highlight specific trends or correlations in fucoxanthin production. The efficiency and environmental impact of extraction methods, such as supercritical fluid extraction, ultrasound-assisted extraction, and microwave-assisted extraction, have also been evaluated. In addition, synthetic biology and Clustered Regularly Interspaced Short Palindromic Repeats (CRISPR)-based genetic modifications show potential for enhancing fucoxanthin biosynthesis. However, challenges remain in terms of cost, scalability, and regulatory constraints. This review highlights the need for integrated biotechnological solutions to enhance commercial viability, combining metabolic engineering, efficient extraction techniques, and optimized cultivation strategies. As demand continues to grow in the nutraceutical, pharmaceutical, and cosmetic industries, ongoing advancements in microalgae-based fucoxanthin production will be critical for ensuring sustainable and cost-effective manufacturing.

The potential of Pavlovophyceae species as a source of valuable carotenoids and polyunsaturated fatty acids for human consumption

Microalgae are a group of microorganisms, mostly photoautotrophs with high CO2 fixation capacity, that have gained increased attention in the last decades due to their ability to produce a wide range of valuable metabolites, such as carotenoids and polyunsaturated fatty acids, for application in food/feed, pharmaceutical, and cosmeceutical industries. Their increasing relevance has highlighted the importance of identifying and culturing new bioactive-rich microalgae species, as well as of a thorough understanding of the growth conditions to optimize the biomass production and master the biochemical composition according to the desired application. Thus, this review intends to describe the main cell processes behind the production of carotenoids and polyunsaturated fatty acids, in order to understand the possible main triggers responsible for the accumulation of those biocompounds. Their economic value and the biological relevance for human consumption are also summarized. In addition, an extensive review of the impact of culture conditions on microalgae growth performance and their biochemical composition is presented, focusing mainly on the studies involving Pavlovophyceae species. A complementary description of the biochemical composition of these microalgae is also presented, highlighting their potential applications as a promising bioresource of compounds for large-scale production and human and animal consumption.

Isolation and Selection of Protein-Rich Mutants of Chlorella vulgaris by Fluorescence-Activated Cell Sorting with Enhanced Biostimulant Activity to Germinate Garden Cress Seeds

Microalgae are a promising feedstock with proven biostimulant activity that is enhanced by their biochemical components (e.g., amino acids and phytohormones), which turns them into an appealing feedstock to reduce the use of fertilisers in agriculture and improve crop productivity and resilience. Thus, this work aimed to isolate protein-rich microalgal mutants with increased biostimulant activity. Random mutagenesis was performed with Chlorella vulgaris, and a selection of protein-rich mutants were sorted through fluorescence-activated cell sorting (FACS), resulting in the isolation of 17 protein-rich mutant strains with protein contents 19-34% higher than that of the wildtype (WT). Furthermore, mutant F4 displayed a 38%, 22% and 62% higher biomass productivity, growth rate and chlorophyll content, respectively. This mutant was then scaled up to a 7 L benchtop reactor to produce biomass and evaluate the biostimulant potential of this novel strain towards garden cress seeds. Compared to water (control), the germination index and the relative total growth increased by 7% and 19%, respectively, after the application of 0.1 g L-1 of this bioproduct, which highlights its biostimulant potential.

Identification and optimization of the key growth parameters involved in carotenoids production of the marine microalga Pavlova gyrans

In this work, a multivariate analysis was carried out, using a Plackett-Burman (PB) design involving seventeen growth parameters, on carotenoids production of Pavlova gyrans (p < 0.10). Each assay was analysed regarding its content (mg g-1) of fucoxanthin (Fx), diatoxanthin, diadinoxanthin, β-carotene (βCar), α-carotene, and the sum of all carotenoids analysed individually (TCar). According to the statistical analysis, modified medium formulations were developed for the particular cases of Fx, βCar, and TCar. The study showed that Fx content was positively affected by nitrogen supplementation and lower light intensities. Higher concentrations of nitrogen and iron increased the final content of βCar as well. Similarly, salinity, light intensity, nitrogen, iron, and cobalt were identified as key factors in TCar production. The PB-based formulations showed significant improvements (p < 0.05) for TCar (11.794 mg g-1) and Fx (6.153 mg g-1) when compared to the control conditions (Walne's medium-2.010 mg g-1). Furthermore, effective control of key variables (e.g., light intensity) throughout P. gyrans growth proved successful (p < 0.05), increasing the productivity of Fx (0.759 mg L-1 d-1) and TCar (1.615 mg L-1 d-1).

Optimizing cultivation strategies and scaling up for fucoxanthin production using Pavlova sp

The microalgal-based production of fucoxanthin has emerged as an imperative research endeavor due to its antioxidant, and anticancer properties. In this study, three brown marine microalgae, namely Skeletonema costatum, Chaetoceros gracilis, and Pavlova sp., were screened for fucoxanthin production. All strains displayed promising results, with Pavlova sp. exhibiting the highest fucoxanthin content (27.91 mg/g) and productivity (1.16 mg/L·day). Moreover, the influence of various cultivation parameters, such as culture media, salinity, sodium nitrate concentration, inoculum size, light intensity, and iron concentration, were investigated and optimized, resulting in a maximum fucoxanthin productivity of 7.89 mg/L·day. The investigation was further expanded to large-scale outdoor cultivation using 50 L tubular photobioreactors, illustrating the potential of Pavlova sp. and the cultivation process for future commercialization. The biomass and fucoxanthin productivity for the large-scale cultivation were 70.7 mg/L·day and 4.78 mg/L·day, respectively. Overall, the findings demonstrated considerable opportunities for fucoxanthin synthesis via microalgae cultivation and processing.

Monitoring Changes to Alkenone Biosynthesis in Commercial Tisochrysis lutea Microalgae

Alkenones are unique lipids produced by certain species of microalgae, well-known for use in paleoclimatology, and more recently pursued to advance sustainability across multiple industries. Beginning in 2018, the biosynthesis of alkenones by commercially grown Tisochrysis lutea (T-Iso) microalgae from one of the world's most established producers, Necton S.A., changed dramatically from structures containing 37 and 38 carbons, to unusual shorter-chain C35 and C36 diunsaturated alkenones (C35:2 and C36:2 alkenones). While the exact reasons for this change remain unknown, analysis of alkenones isolated from T-Iso grown in 2021 and 2023 revealed that this change has persisted. The structure of these rare shorter-chain alkenones, including double bond position, produced by Necton T-Iso remained the same over the last five years, which was determined using a new and optimized cross-metathesis derivatization approach with analysis by comprehensive two-dimensional gas chromatography and NMR. However, noticeable differences in the alkenone profiles among the different batches were observed. Combined with fatty acid compositional analysis, the data suggest a connection between these lipid classes (e.g., increased DHA corresponds to lower amounts of shorter-chain alkenones) and the ability to manipulate their biosynthesis in T-Iso with changes to cultivation conditions.

Fucoxanthin Production of Microalgae under Different Culture Factors: A Systematic Review

Fucoxanthin is one of the light-harvesting pigments in brown microalgae, which is increasingly gaining attention due to its numerous health-promoting properties. Currently, the production of microalgal fucoxanthin is not yet feasible from an economic perspective. However, the cultivation of microalgae at favourable conditions holds great potential to increase the viability of this fucoxanthin source. Hence, this study aimed to review the fucoxanthin production of microalgae under different conditions systematically. A literature search was performed using the Web of Science, Scopus and PubMed databases. A total of 188 articles were downloaded and 28 articles were selected for the current review by two independent authors. Microalgae appeared to be a more reliable fucoxanthin source compared to macroalgae. Overall, a consensus fucoxanthin production condition was obtained and proposed: light intensity ranging from 10 to 100 µmol/m²/s could achieve a higher fucoxanthin content. However, the optimal light condition in producing fucoxanthin is species-specific. The current review serves as an antecedent by offering insights into the fucoxanthin-producing microalgae response to different culture factors via a systematic analysis. With the current findings and recommendations, the feasibility of producing fucoxanthin commercially could be enhanced and possibly achieve practical and sustainable fucoxanthin production.

Mild acoustic processing of Tisochrysis lutea for multiproduct biorefineries

Cellular agriculture could represent a more sustainable alternative to current food and nutraceutical production processes. Tisochrysis lutea microalgae represents a rich source of antioxidants and omega-3 fatty acids essential for human health. However, current downstream technologies are limiting its use. The present work investigates mild targeted acoustic treatment of Tisochrysis lutea biomass at different growth stages and acoustic frequencies, intensities and treatment times. Significant differences have been observed in terms of the impact of these variables on the cell disruption and energy requirements. Lower frequencies of 20 kHz required a minimum of 4500 J to disrupt 90% of the cells, while only 1000 J at 1146 kHz. Comparing these results with current industry standards such as bead milling, up to six times less energy use has been identified. These mild biomass processing approaches offer a certain tunability which could suit a wide range of microorganisms with only minor adjustments.

Random Mutagenesis as a Promising Tool for Microalgal Strain Improvement towards Industrial Production

Microalgae have become a promising novel and sustainable feedstock for meeting the rising demand for food and feed. However, microalgae-based products are currently hindered by high production costs. One major reason for this is that commonly cultivated wildtype strains do not possess the robustness and productivity required for successful industrial production. Several strain improvement technologies have been developed towards creating more stress tolerant and productive strains. While classical methods of forward genetics have been extensively used to determine gene function of randomly generated mutants, reverse genetics has been explored to generate specific mutations and target phenotypes. Site-directed mutagenesis can be accomplished by employing different gene editing tools, which enable the generation of tailor-made genotypes. Nevertheless, strategies promoting the selection of randomly generated mutants avoid the introduction of foreign genetic material. In this paper, we review different microalgal strain improvement approaches and their applications, with a primary focus on random mutagenesis. Current challenges hampering strain improvement, selection, and commercialization will be discussed. The combination of these approaches with high-throughput technologies, such as fluorescence-activated cell sorting, as tools to select the most promising mutants, will also be discussed.

Fucoxanthin from Algae to Human, an Extraordinary Bioresource: Insights and Advances in up and Downstream Processes

Fucoxanthin is a brown-colored pigment from algae, with great potential as a bioactive molecule due to its numerous properties. This review aims to present current knowledge on this high added-value pigment. An accurate analysis of the biological function of fucoxanthin explains its wide photon absorption capacities in golden-brown algae. The specific chemical structure of this pigment also leads to many functional activities in human health. They are outlined in this work and are supported by the latest studies in the literature. The scientific and industrial interest in fucoxanthin is correlated with great improvements in the development of algae cultures and downstream processes. The best fucoxanthin producing algae and their associated culture parameters are described. The light intensity is a major influencing factor, as it has to enable both a high biomass growth and a high fucoxanthin content. This review also insists on the most eco-friendly and innovative extraction methods and their perspective within the next years. The use of bio-based solvents, aqueous two-phase systems and the centrifugal partition chromatography are the most promising processes. The analysis of the global market and multiple applications of fucoxanthin revealed that Asian companies are major actors in the market with macroalgae. In addition, fucoxanthin from microalgae are currently produced in Israel and France, and are mostly authorized in the USA.

Improved high-throughput screening technique to rapidly isolate Chlamydomonas transformants expressing recombinant proteins

Abstract

The single-celled eukaryotic green alga Chlamydomonas reinhardtii has long been a model system for developing genetic tools for algae, and is also considered a potential platform for the production of high-value recombinant proteins. Identifying transformants with high levels of recombinant protein expression has been a challenge in this organism, as random integration of transgenes into the nuclear genome leads to low frequency of cell lines with high gene expression. Here, we describe the design of an optimized vector for the expression of recombinant proteins in Chlamydomonas, that when transformed and screened using a dual antibiotic selection, followed by screening using fluorescence activated cell sorting (FACS), permits rapid identification and isolation of microalgal transformants with high expression of a recombinant protein. This process greatly reduces the time required for the screening process, and can produce large populations of recombinant algae transformants with between 60 and 100% of cells producing the recombinant protein of interest, in as little as 3 weeks, that can then be used for whole population sequencing or individual clone analysis. Utilizing this new vector and high-throughput screening (HTS) process resulted in an order of magnitude improvement over existing methods, which normally produced under 1% of algae transformants expressing the protein of interest. This process can be applied to other algal strains and recombinant proteins to enhance screening efficiency, thereby speeding up the discovery and development of algal-derived recombinant protein products.

Key points

• A protein expression vector using double-antibiotic resistance genes was designed

• Double antibiotic selection causes fewer colonies with more positive for phenotype

• Coupling the new vector with FACS improves microalgal screening efficiency > 60%

Supplementary Information

The online version contains supplementary material available at 10.1007/s00253-022-11790-9.

Paradigm shift in algal biomass refinery and its challenges

Microalgae have been studied and tested for over 70 years. However, biodiesel, the prime target of the algal industry, has suffered from low competitiveness and current steps toward banning the internal combustion engine all over the world. Meanwhile, interest in reducing CO₂ emissions has grown as the world has witnessed disasters caused by global warming. In this situation, in order to maximize the benefits of the microalgal industry and surmount current limitations, new breakthroughs are being sought. First, drop-in fuel, mandatory for the aviation and maritime industries, has been discussed as a new product. Second, methods to secure stable and feasible outdoor cultivation focusing on CO₂ sequestration were investigated. Lastly, the need for an integrated refinery process to simultaneously produce multiple products has been discussed. While the merits of microalgae industry remain valid, further investigations into these new frontiers would put algal industry at the core of future bio-based economy.

Producing fucoxanthin from algae - Recent advances in cultivation strategies and downstream processing

Fucoxanthin, a brown-colored pigment from algae, is gaining much attention from industries and researchers recently due to its numerous potential health benefits, including anti-oxidant, anti-cancer, anti-obesity functions, and so on. Although current commercial production is mainly from brown macroalgae, microalgae with rapid growth rate and much higher fucoxanthin content demonstrated higher potential as the fucoxanthin producer. Factors such as concentration of nitrogen, iron, silicate as well as light intensity and wavelength play a significant role in fucoxanthin biosynthesis from microalgae. Two-stage cultivation approaches have been proposed to maximize the production of fucoxanthin and other valuable metabolites. Sustainable fucoxanthin production can be achieved by using low-cost substrates as a culture medium in an open pond cultivation system utilizing seawater with nutrient recycling. For downstream processing, the integration of novel "green" solvents with other extraction techniques emerged as a promising extraction technique.

Maximizing fucoxanthin production in Odontella aurita by optimizing the ratio of red and blue light-emitting diodes in an auto-controlled internally illuminated photobioreactor

Fucoxanthin has multiple beneficial effects on human health. However, an efficient cultivation strategy for hyper-production of microalgae-based fucoxanthin has been seldom achieved. Here, an auto-controlled photobioreactor (PBR) installed internal light-emitting diodes illumination with adjustable spectra ratio was firstly used to culture Odontella aurita. The results showed that red light (RL) was more suitable for cell growth and fucoxanthin accumulation than blue light (BL) and white light. The biomass and fucoxanthin production were further promoted by optimizing the ratios of RL and BL, with 8:2 giving the highest productivities of 570 and 9.41 mg L-1 d-1, respectively, which is the highest fucoxanthin productivity ever reported under photoautotrophic cultivation. Pilot-scale cultivation demonstrated its promising feasibility in commercial fucoxanthin production. Our study represents a pioneering work of harnessing the PBR with internal illumination for hyper-production of microalgae-based fucoxanthin, and provides feasible strategies for high-efficient production of other value-added products in related species/strains.

A review on the progress, challenges and prospects in commercializing microalgal fucoxanthin

Fucoxanthin, the most abundant but nearly untapped carotenoid resource, is in the spotlight in the last decade from various perspectives due to a wide range of bioactivities and healthy benefits. The exploitation of fucoxanthin for nutraceutical and pharmaceutical purposes encompasses enormous scientific and economic potentials. Traditional production of fucoxanthin from brown algae (macroalgae) is constrained by limited yield and prohibitively high cost. Microalgae, as the most diverse photoautotrophs, hold the promises as sustainable sources and ideal cell factories for commercial fucoxanthin production, owing to their rich fucoxanthin content and excellent biomass productivity. In this work, the recent progress in upstream (microalgae selection, optimization of culture conditions, trophic modes, cultivation strategies and biosynthesis pathway) as well as downstream processes (extraction) of fucoxanthin production has been comprehensively and critically reviewed. The major bottlenecks, such as screening of fucoxanthin-producers, conflict between biomass and fucoxanthin accumulation under high light condition, unclear steps in biosynthesis pathway and limited evaluation of outdoor scale-up cultivation and extraction, have been pinpointed. Most importantly, the applications of emerging and conventional techniques facilitating commercialization of microalgal fucoxanthin are highlighted. The reviewed and evaluated include breeding and high-throughput screening methods of elite strains; flashing light effect inducing concurrent biomass and fucoxanthin accumulation; fucoxanthin biosynthesis and the regulatory mechanisms associating with its accumulation elucidated with the development of genetic engineering and omics techniques; and photobioreactors, harvesting and extraction techniques suitable for scaling up fucoxanthin production. In conclusion, the prospects of microalgal fucoxanthin commercialization can be expected with the joint development of fundamental phycology and biotechnology.

Fucoxanthin and docosahexaenoic acid production by cold-adapted Tisochrysis lutea

Tisochrysis lutea is an important microalgal species for fucoxanthin and docosahexaenoic acid (DHA) production with an optimum cultivation temperature of approximately 30 °C. The aim of the present work was to develop a winter strain with high productivity at 15 °C. The response of the original strain to a decrease in temperature from 30 °C to 15 °C was investigated in continuous turbidostat experiments. This was followed by adaptation for >180 days at 15 °C and 2 rounds of sorting for cells with high chlorophyll fluorescence (top 5%) using fluorescence-activated cell sorting (FACS). For the original strain the productivity of biomass, fucoxanthin, and DHA decreased by 92 %, 98 % and 85 % respectively when decreasing the temperature from 30 °C to 15 °C. In the sorted cold-adapted 'winter strain', biomass, fucoxanthin, and DHA productivities were similar to those at 30 °C. In addition, the fucoxanthin concentration increased from 1.11 to 4.24 mg g^-1 dry weight and the polar lipid fraction in total fatty acids increased from 21 % to 55 %. The winter strain showed a robust and stable phenotype after one year of cultivation, expanding the outdoor fucoxanthin and lipid production seasons for this species.

Unconventional high-value products from microalgae: A review

Microalgae have gained significant importance in biotechnology development, providing valuable goods and services in multiple applications. Although there is a rising market for most of these applications, the incorporation and introduction of microalgae into new venues will extend in the near future. These advances are due to the vast biodiversity of microalgal species, recent genetic engineering tools, and culture techniques. There are three main possible approaches for novel algal compounds from: (1) recently isolated yet less known microalgae; (2) selectively stressed conditions; and (3) enzymatically adjusted compounds from conventional molecules. All these approaches can be combined in a specific manner. This review discusses the opportunities, potential and limitations of introducing novel microalgae-based products, and how the recent technologies can be deployed to make these products financially viable. To give an outlook to the future, an analysis of the developments and predicted future market that further enlarge the promise of cultivating microalgae for commercial purposes are considered.