H2020 BIOSEA Project: Innovative and cost-effective technology to maximize aquatic biomass-based molecules for food, feed, and cosmetic applications

The project focused on the validation and scale-up of a complete ingredient production process from four algae, using a cascade biorefinery approach including pretreatment, fractionation, and conversion technologies, for use in food, feed, and cosmetic products. It resulted in a range of replacement ingredients from microalgae (Spirulina platensis and Nannochloropsis sp.) and macroalgae (Ulva ohnoi and Saccharina latissima). In this regard, IGV optimized, cultivated (up to pilot scale), and harvested biomass of the microalgae Spirulina platensis and Nannochloropsis sp., produced in indoor closed photobioreactors using glass photobioreactors and MUTL®, the "ultra-fine mesh layer technology." This optimization process involved the control of parameters such as nutrients, light, CO2, and temperature, thus achieving an increase in the yield of the ingredients of interest.

CTAQUA focused on growing the macroalgae (Ulva ohnoi) in laboratory photobioreactors, later expanding it to open ponds and growing it in cages, prioritizing planting, harvesting, and protection from invasive species.

Meanwhile, AT-SEA Nova optimized a patented advanced textile crop of Saccharina latissima in European seas, focusing on seeding technology, timing and harvesting, and adaptation to climatic influences. This innovative approach, which replaces conventional 2D rope, offers higher production yields thanks to a larger cultivation area.

Researchers from VITO, CNTA, and Feyecon have developed and expanded "zero-waste" extraction protocols, tailored to each of the project's four algae strains, with the goal of extracting useful products in a cascade, so that each refining step produces new, useful products and nothing is discarded. The reagents and chemicals used have been selected to ensure maximum sustainability. This has resulted in a range of algae replacement ingredients, including proteins, phycocyanin, fatty acids, carbohydrates, carotenoids, lipids, and sugar-enriched extracts.

BIOPOLIS, CNTA, and AITEX have identified added value in the algae products obtained, applicable to the industries covered by the project, including antimicrobial effects, UV protection, fat reduction, and antioxidant properties.

These compounds are used in the development of functional foods, animal feed, and cosmetic products, with the goal of replacing conventional ingredients, which can be imported or generate contamination, with high-value-added algae ingredients. Furthermore, VLCI determined the solubility and compatibility properties of these ingredients using Hansen's solubility parameter workflow to efficiently identify compatible ingredients and formulate them with maximum efficacy.

For example, Soria Natural has replaced soy protein with algae protein for vegetarian burgers; CPCFEED suggested replacing fish plasma with algae protein and included microalgae biomass in piglet feed; DIBAQ and CTAQUA experimented with replacing proteins and polysaccharides in fish diets and developed antioxidants; and HENKEL tested other algae-derived ingredients, such as lipids or sugars, for use in cosmetic products, such as marine fertilizers, algae caviar, and personal care products.

TABU conducted an LCA and sLCA assessment to validate the feasibility of this complete production process for algae ingredients in industrial products, considering the definition of each product profile and the social acceptance of this new, sustainable source of ingredients.