Spray-drying of Dunaliella salina to produce a ? -carotene rich powder

Spray Drying Is a Viable Technology for the Preservation of Recombinant Proteins in Microalgae

Microalgae are promising host organisms for the production of encapsulated recombinant proteins such as vaccines. However, bottlenecks in bioprocess development, such as the drying stage, need to be addressed to ensure feasibility at scale. In this study, we investigated the potential of spray drying to produce a recombinant vaccine in microalgae. A transformant line of Chlamydomonas reinhardtii carrying a subunit vaccine against salmonid alphavirus was created via chloroplast engineering. The integrity of the recombinant protein after spray drying and its stability after 27 months storage at -80 °C, +4 °C and room temperature were assessed by immunoblotting. The protein withstood spray drying without significant losses. Long-term storage at +4 °C and room temperature resulted in 50% and 92% degradation, respectively. Optimizing spray drying and storage conditions should minimize degradation and favour short-term storage at positive temperatures. Using data on yield and productivity, the economics of spray drying- and freeze drying-based bioprocesses were compared. The drying stage corresponded to 41% of the total production cost. Process optimization, genetic engineering and new market strategies were identified as potential targets for cost reduction. Overall, this study successfully demonstrates the suitability of spray drying as a process option for recombinant protein production in microalgae at the industrial scale.

Optimization of Astaxanthin Recovery in the Downstream Process of Haematococcus pluvialis

Astaxanthin derived from Haematococcus pluvialis is a valuable metabolite applied in a wide range of products. Its extraction depends on a sophisticated series of downstream process steps, including harvesting, disruption, drying, and extraction, of which some are dependent on each other. To determine the processes that yield maximum astaxanthin recovery, bead milling, high-pressure homogenization, and no disruption of H. pluvialis biomass were coupled with spray-drying, vacuum-drying, and freeze-drying in all possible combinations. Eventually, astaxanthin was extracted using supercritical CO2. Optimal conditions for spray-drying were evaluated through the design of experiments and standard least squares regression (feed rate: 5.8 mL/min, spray gas flow: 400 NL/h, inlet temperature: 180 °C). Maximal astaxanthin recoveries were yielded using high-pressure homogenization and lyophilization (85.4%). All combinations of milling or high-pressure homogenization and lyophilization or spray-drying resulted in similar recoveries. Bead milling and spray-drying repeated with a larger spray-dryer resulted in similar astaxanthin recoveries compared with the laboratory scale. Smaller astaxanthin recoveries after the extraction of vacuum-dried biomass were mainly attributed to textural changes. Evaluation of these results in an economic context led to a recommendation for bead milling and spray-drying prior to supercritical CO2 extraction to achieve the maximum astaxanthin recoveries.

Valorizing okara waste into nutritionally rich polysaccharide/protein-extracts for co-encapsulation of β-carotene and ferrous sulphate as a potential approach to tackle micronutrient malnutrition

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Okara was upcycled into encapsulation materials using microwave assisted technique.

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Okara and zein as excipient used as encapsulation substrate for micronutrients.

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The formulation produced desirable sequential release of micronutrients in SGF and SIF.

Colossal amounts of food waste are generated and discarded daily at the expense of financial resources and at a detriment to the environment. One such food waste, okara – a soybean by-product, is valorized in this study by upcycling it into nutritional extracts for micronutrients encapsulation. Micronutrient malnutrition, particularly in the developing world, is a major public health challenge. Herein, okara extracts were obtained through a low-cost extraction process and was subsequently developed as an encapsulant material for micronutrients β-carotene, and ferrous sulphate encapsulation, using zein as an excipient. Spray-drying, as a scalable technique, was employed to produce various formulations which were assessed for release profiles, shelf-life, β-carotene antioxidant activity and cell cytotoxicity. Finally, an optimized dual-micronutrient formulation displayed a sequential release with ferrous sulphate releasing in simulated gastric fluid, and β-carotene releasing predominantly in simulated intestinal fluid. This sequential release profile favors the absorption of both the micronutrients and could potentially enhance their bioavailability.

Effect of rice bran protein concentrate as wall material adjunct on selected physicochemical and release properties of microencapsulated β-carotene

Rice bran protein is an emerging protein source from rice milling that possesses health benefits and emulsifying capacity suitable for hypoallergenic encapsulation applications, especially for lipophilic compounds such as β-carotene. The purpose of this study is to develop and characterize β-carotene encapsulates with maltodextrin and rice bran protein. Rice bran protein was prepared using conventional alkali extraction. β-carotene was added to the composite wall materials (50:50 of 4%, 8%, 12%, and 16% solids content) and spray-dried. Encapsulation efficiency (85-98%) and radical scavenging activity (11-43%) varied proportionally with rice bran protein. Across increasing maltodextrin and rice bran protein content of the feed, carbohydrate content of the microcapsules varied proportionally (50-66%) but protein content was uniform (10-13%). Scanning electron microscopy, differential scanning calorimetry, and Fourier transform infrared spectroscopy data suggested successful encapsulation. Release profiles showed decreasing trend with increasing rice bran protein content; co-digestion with rice mitigated negative impacts of rice bran protein. Microcapsules with nutritive potential and health-promoting properties were developed as potential carotenoid delivery systems.

The influence of nanodelivery systems on the antioxidant activity of natural bioactive compounds

Bioactive compounds may lose their antioxidant activity (e.g., phenolic compounds) at elevated temperatures, enhanced oxidative conditions and severe light exposures so they should be protected by various strategies such as nano/microencapsulation methods. Encapsulation technology has been employed as a proper method for using antioxidant ingredients and to provide easy dispersibility of antioxidants in all matrices including food and pharmaceutical products. It can improve the food fortification processes, release of antioxidant ingredients, and extending the shelf-life and bioavailability of them when ingested in the intestine. In this study, our main goal is to have an overview of the influence of nanoencapsulation on the bioactivity and bioavailability, and cellular activities of antioxidant ingredients in different delivery systems. Also, the effect of encapsulation process conditions, storage conditions, carrier wall materials, and release profile on the antioxidant activity of different natural bioactives are explained. Finally, analytical techniques for measuring antioxidant activity of nanoencapsulated ingredients will be covered.

Microalgae Encapsulation Systems for Food, Pharmaceutical and Cosmetics Applications

Microalgae are microorganisms with a singular biochemical composition, including several biologically active compounds with proven pharmacological activities, such as anticancer, antioxidant and anti-inflammatory activities, among others. These properties make microalgae an interesting natural resource to be used as a functional ingredient, as well as in the prevention and treatment of diseases, or cosmetic formulations. Nevertheless, natural bioactives often possess inherent chemical instability and/or poor solubility, which are usually associated with low bioavailability. As such, their industrial potential as a health-promoting substance might be severely compromised. In this context, encapsulation systems are considered as a promising and emerging strategy to overcome these shortcomings due to the presence of a surrounding protective layer. Diverse systems have already been reported in the literature for natural bioactives, where some of them have been successfully applied to microalgae compounds. Therefore, this review focuses on exploring encapsulation systems for microalgae biomass, their extracts, or purified bioactives for food, pharmaceutical, and cosmetic purposes. Moreover, this work also covers the most common encapsulation techniques and types of coating materials used, along with the main findings regarding the beneficial effects of these systems.

A review of encapsulation of carotenoids using spray drying and freeze drying

Carotenoids are potent antioxidants, but they are highly unstable and susceptible during processing and storage. Encapsulation technologies protect against degradation and are capable of releasing individual or combination of bioactive substances during processing as well as development of various functional food products. Moreover, encapsulating agents can be used to increase the stability of carotenoids and form a barrier between the core and wall materials. Suitable encapsulating agents, temperature, and drying methods are the most important factors for the encapsulation process. In this report, we reviewed the current status of encapsulation of carotenoids from different fruits, vegetables, spices, seaweeds, microorganisms, and synthetic sources using various types of encapsulating agents through spray drying and freeze drying. We also focused on the degradation kinetics and various factors that affect the stability and bioavailability of encapsulated carotenoids during their processing and storage.

Capture-Ferment-Upgrade: A Three-Step Approach for the Valorization of Sewage Organics as Commodities

This critical review outlines a roadmap for the conversion of chemical oxygen demand (COD) contained in sewage to commodities based on three-steps: capture COD as sludge, ferment it to volatile fatty acids (VFA), and upgrade VFA to products. The article analyzes the state-of-the-art of this three-step approach and discusses the bottlenecks and challenges. The potential of this approach is illustrated for the European Union's 28 member states (EU-28) through Monte Carlo simulations. High-rate contact stabilization captures the highest amount of COD (66-86 g COD person equivalent^-1 day^-1 in 60% of the iterations). Combined with thermal hydrolysis, this would lead to a VFA-yield of 23-44 g COD person equivalent^-1 day^-1. Upgrading VFA generated by the EU-28 would allow, in 60% of the simulations, for a yearly production of 0.2-2.0 megatonnes of esters, 0.7-1.4 megatonnes of polyhydroxyalkanoates or 0.6-2.2 megatonnes of microbial protein substituting, respectively, 20-273%, 70-140% or 21-72% of their global counterparts (i.e., petrochemical-based esters, bioplastics or fishmeal). From these flows, we conclude that sewage has a strong potential as biorefinery feedstock, although research is needed to enhance capture, fermentation and upgrading efficiencies. These developments need to be supported by economic/environmental analyses and policies that incentivize a more sustainable management of our resources.

Halobacterium salinarum storage and rehydration after spray drying and optimization of the processes for preservation of carotenoids

Spray drying is appropriate for the preservation of halophilic microorganisms due to the nature of these microorganisms, as they survive in adverse environmental conditions by being encapsulated in salt crystals. Artificial neural networks were in this study used to optimize practically significant spray-drying regimes of the C₅₀-carotenoids producer Halobacterium salinarum. Immediately after drying, the samples contained up to 54% halobacterial biomass and less than 5% moisture, and the level of preservation of carotenoids was 95-97%. The storage of biomass at 4 °C resulted in the gradual degradation of the carotenoids, which reached 58-64% in the best samples after 1 year. A comprehensive study of changes in halobacteria biomass after spray drying and the nature of the damage provided new data on the survival and preservation of cells and biologically active substances in the various spray-drying regimes and at different storage times.

In Vitro Effectiveness of Microspheres Based on Silk Sericin and Chlorella vulgaris or Arthrospira platensis for Wound Healing Applications

Some natural compounds have recently been widely employed in wound healing applications due to their biological properties. One such compound is sericin, which is produced by Bombix mori, while active polyphenols, polysaccharides and proteins are synthetized by Chlorella vulgaris and Arthrospira platensis microalgae. Our hypothesis was that sericin, as an optimal bioactive polymeric carrier for microencapsulation process, could also improve the regenerative effect of the microalgae. A solvent-free extraction method and spray drying technique were combined to obtain five formulations, based on algal extracts (C. vulgaris and A. platensis, Chl and Art, respectively) or silk sericin (Ser) or their mixtures (Chl-Ser and Art-Ser). The spray drying was a suitable method to produce microspheres with similar dimensions, characterized by collapsed morphology with a rough surface. Art and Art-Ser showed higher antioxidant properties than other formulations. All microspheres resulted in cytocompatibility on fibroblasts until 1.25 mg/mL and promoted cell migration and the complete wound closure; this positive effect was further highlighted after treatment with Art and Art-Ser. To our surprize the combination of sericin to Art did not improve the microalgae extract efficacy, at least in our experimental conditions.

Algae to Economically Viable Low-Carbon-Footprint Oil

Algal oil as an alternative to fossil fuel has attracted attention since the 1940s, when it was discovered that many microalgae species can produce large amounts of lipids. Economics and energy security were the motivational factors for a spurt in algae research during the 1970s, 1990s, and early 2000s. Whenever crude prices declined, research on algae stopped. The scenario today is different. Even given low and volatile crude prices ($30-$50/barrel), interest in algae continues all over the world. Algae, with their cure-all characteristics, have the potential to provide sustainable solutions to problems in the energy-food-climate nexus. However, after years of effort, there are no signs of algae-to-biofuel technology being commercialized. This article critically reviews past work; summarizes the current status of the technology; and based on the lessons learned, provides a balanced perspective on a potential path toward commercialization of algae-to-oil technology.

Scope of algae as third generation biofuels

An initiative has been taken to develop different solid, liquid, and gaseous biofuels as the alternative energy resources. The current research and technology based on the third generation biofuels derived from algal biomass have been considered as the best alternative bioresource that avoids the disadvantages of first and second generation biofuels. Algal biomass has been investigated for the implementation of economic conversion processes producing different biofuels such as biodiesel, bioethanol, biogas, biohydrogen, and other valuable co-products. In the present review, the recent findings and advance developments in algal biomass for improved biofuel production have been explored. This review discusses about the importance of the algal cell contents, various strategies for product formation through various conversion technologies, and its future scope as an energy security.

Effects of spray-drying and storage on astaxanthin content of Haematococcus pluvialis biomass

The main objective of this study was to evaluate the stability of astaxanthin after drying and storage at different conditions during a 9-week period. Recovery of astaxanthin was evaluated by extracting pigments from the dried powders and analysing extracts by HPLC. The powders obtained were stored under different conditions of temperature and oxygen level and the effects on the degradation of astaxanthin were examined. Under the experimental conditions conducted in this study, the drying temperature that yielded the highest content of astaxanthin was 220°C, as the inlet, and 120°C, as the outlet temperature of the drying chamber. The best results were obtained for biomass dried at 180/110°C and stored at -21°C under nitrogen, with astaxanthin degradation lower than 10% after 9 weeks of storage. A reasonable preservation of astaxanthin can be achieved by conditions 180/80°C, -21°C nitrogen, 180/110°C, 21°C nitrogen, and 220/80°C, 21°C vacuum: the ratio of astaxanthin degradation is equal or inferior to 40%. In order to prevent astaxanthin degradation of Haematococcus pluvialis biomass, it is recommended the storage of the spray dried carotenized cells (180/110ºC) under nitrogen and -21°C.

Stability of beta-carotene in spray dried preparation of Rhodotorula glutinis mutant 32

AIMS

To obtain beta-carotene-rich dry cell preparation from mutant 32 of Rhodotorula glutinis and determination of its pigment stability.

METHODS AND RESULTS

The mutant 32 of R. glutinis was grown in a 14 l stirred tank fermenter. Cell mass was concentrated 10-fold by cross-flow microfiltration and then spray dried. Butylated hydroxy toluene (BHT) and d-tocopherol were used as protecting agents. A two-level, three-variable, factorial optimization was performed to achieve moisture-free, non-viable and beta-carotene-rich feed additive.

CONCLUSIONS

The beta-carotene and cell mass in stirred tank fermenter were found to be 54 +/- 5 mg l-1 and 12.8 +/- 2 g l-1, respectively. In the presence of BHT, 97 +/- 3% (w/w) beta-carotene was recovered for all the inlet temperatures studied. The best beta-carotene and yeast powder recoveries were obtained at 160 degrees C, 11.6% (w/v) cell mass concentration and 1 g l-1 BHT. The pigments inside dried yeast powder were stable in dark and cold condition for at least 10 weeks. The purified beta-carotene got almost totally denatured, under similar conditions of storage, within 76 h.

SIGNIFICANCE AND IMPACT OF THE STUDY

Spray dried and stable preparation of beta-carotene-rich yeast, R. glutinis can provide alternative source of beta-carotene for use in animal nutrition.

Spray-drying of the microalga Dunaliella salina: effects on beta-carotene content and isomer composition

The effects of spray-drying of the unicellular microalga Dunaliella salina on its beta-carotene content and geometric isomer composition have been studied. The efficacy of a range of synthetic and natural antioxidants in preventing degradation of beta-carotene has been determined. Losses of beta-carotene and isomerization were minimal during processing for both the control (no exogenous antioxidants) and the samples containing butylated hydroxytoluene (BHT) and tert-butylhydroquinone (TBHQ). However, the use of tocopherol-based antioxidants resulted in degradation of 52-72% of beta-carotene during the drying process. All dried powders of Dunaliella proved to be unstable during storage in the presence of light and air, with beta-carotene degraded according to a first-order kinetic model. Of the antioxidants studied, only TBHQ was successful in significantly minimizing degradation (degradation constants of 0.03 and 0.04 days(-)(1), compared to 0.53 days(-)(1) for the respective control). For control powders and those with BHT added to the feed, the degradation constants were reduced to values between 0.27 and 0.37 days(-)(1) by restricting light and flushing with nitrogen; however, storage in the dark alone had no effect. For more slowly degrading powders having TBHQ added to the feed, it was clear that degradation of beta-carotene was influenced by both light and oxygen. During storage the 9-cis isomer of beta-carotene was significantly more unstable than the all-trans form. TBHQ was, however, successful in reducing relative losses of this isomer for samples stored in the dark. The results suggest a dominant photodegradative mechanism for the loss of the 9-cis isomer of beta-carotene.