Enhancing lutein production with Chlorella sorokiniana Mb-1 by optimizing acetate and nitrate concentrations under mixotrophic growth

Evolving perspectives on lutein production from microalgae - A focus on productivity and heterotrophic culture

Increased consumer awareness for healthier and more sustainable products has driven the search for naturally sourced compounds as substitutes for chemically synthesized counterparts. Research on pigments of natural origin, such as carotenoids, particularly lutein, has been increasing for over three decades. Lutein is recognized for its antioxidant and photoprotective activity. Its ability to cross the blood-brain barrier allows it to act at the eye and brain level and has been linked to benefits for vision, cognitive function and other conditions. While marigold flower is positioned as the only crop from which lutein is extracted from and commercialized, microalgae are proposed as an alternative with several advantages over this terrestrial crop. The main barrier to scaling up lutein production from microalgae to the commercial level is the low productivity compared to the high costs. This review explores strategies to enhance lutein production in microalgae by emphasizing the overall productivity over lutein content alone. Evaluation of how culture parameters, such as light quality, nitrogen sufficiency, temperature and even stress factors, affect lutein content and biomass development in batch phototrophic cultures was performed. Overall, the total lutein production remains low under this metabolic regime due to the low biomass productivity of photosynthetic batch cultures. For this reason, we describe findings on microalgal cultures grown under different metabolic regimes and culture protocols (fed-batch, pulse-feed, semi-batch, semi-continuous, continuous). After a careful literature examination, two-step heterotrophic or mixotrophic cultivation strategies are suggested to surpass the lutein productivity achieved in single-step photosynthetic cultures. Furthermore, this review highlights the urgent need to develop technical feasibility studies at a pilot scale for these cultivation strategies, which will strengthen the necessary techno-economic analyses to drive their commercial production.

Lutein Production and Extraction from Microalgae: Recent Insights and Bioactive Potential

Microalgae have been reported to be excellent producers of bioactive molecules. Lutein is a pigment reported to have various beneficial effects for humans, and especially for eye well-being. In the current review, we summarize various methods that have been developed to optimize its extraction and bioactivities reported for human health. Several protective effects have been reported for lutein, including antioxidant, anticancer, anti-inflammatory, and cardioprotective activity. This review also reports attempts to increase lutein production by microalgae by changing culturing parameters or by using pilot-scale systems. Genetic engineering lutein production is also discussed. Considering the increasing aging of the worldwide population will create an increased need for lutein, a viable economic and eco-sustainable method to produce lutein is needed to face this market demand.

Abiotic stress as a dynamic strategy for enhancing high value phytochemicals in microalgae: Critical insights, challenges and future prospects

Microalgae showcase an extraordinary capacity for synthesizing high-value phytochemicals (HVPCs), offering substantial potential for diverse applications across various industries. Emerging research suggests that subjecting microalgae to abiotic stress during cultivation and the harvesting stages can further enhance the accumulation of valuable metabolites within their cells, including carotenoids, antioxidants, and vitamins. This study delves into the pivotal impacts of manipulating abiotic stress on microalgae yields, with a particular focus on biomass and selected HVPCs that have received limited attention in the existing literature. Moreover, approaches to utilising abiotic stress to increase HVPCs production while minimising adverse effects on biomass productivity were discussed. The present study also encompasses a techno-economic assessment (TEA) aimed at pinpointing significant bottlenecks in the conversion of microalgae biomass into high-value products and evaluating the desirability of various conversion pathways. The TEA methodology serves as a valuable tool for both researchers and practitioners in the quest to identify sustainable strategies for transforming microalgae biomass into high-value products and goods. Overall, this comprehensive review sheds light on the pivotal role of abiotic stress in microalgae cultivation, promising insights that could lead to more efficient and sustainable approaches for HVPCs production.

Optimization of 4-aminobutyric acid feeding strategy and clustered regularly interspaced short palindromic repeats activation for enhanced value-added chemicals in halophilic Chlorella sorokiniana

Chlorella sorokiniana (CS) is a prominent microalga with vast potential as a biocarrier for carbon mitigation toward a green process. However, challenges remain in achieving high biomass levels and production rates. Therefore, a systematic feeding strategy using 4-aminobutyric acid (GABA) and CRISPR technology was applied to improve microalgal productivity. At first, GABA increased protein content by 1.4-fold, while intermittent supplementation during cultivation resulted in a 1.58-fold and 2.13-fold increase in biomass and pigment content, respectively. Under halophilic conditions, the optimal approach involved repeated feeding of 5 mM GABA at the initial and mid-log phases of growth, resulting in biomass, protein, and pigment levels of 6.74 g/L, 3.24 g/L, and 49.87 mg/L. CRISPRa mediated glutamate synthase and using monosodium glutamate (MSG) as a cheap precursor for GABA has effectively enhanced the biomass, protein, and lutein content, thus offers a cost-effective approach to commercialize high-valued chemical using algae towards a low-carbon paradigm.

Lutein production from microalgae: A review

Lutein production from microalgae is a sustainable and economical strategy to offer the increasing global demands, but is still challenged with low lutein content at the high-cell density for commercial production. This review summarizes the suitable conditions for cell growth and lutein accumulation, and presents recent cultivation strategies to further improve lutein productivity. Light and nitrogen play critical roles in lutein biosynthesis that lead to the efficient multi-stage cultivation by increasing lutein content at the later stage. In addition, metabolic and genetic designs for carbon regulation and lutein biosynthesis are discussed at the molecule level. The in-situ lutein accumulation in fermenters by regulating carbon metabolism is considered as a cost-effective direction. Then, downstream processes are summarized for the efficient lutein recovery. Finally, challenges of current lutein production from microalgae are discussed. Meanwhile, potential solutions are proposed to improve lutein content and drive down costs of microalgal biomass.

A universal dynamical metabolic model representing mixotrophic growth of Chlorella sp. on wastes

An emerging idea is to couple wastewater treatment and biofuel production using microalgae to achieve higher productivities and lower costs. This paper proposes a metabolic modeling of Chlorella sp. growing on fermentation wastes (blend of acetate, butyrate and other acids) in mixotrophic conditions, accounting also for the possible inhibitory substrates. This model extends previous works by modifying the metabolic network to include the consumption of glycerol and glucose by Chlorella sp., with the goal to test the addition of these substrates in order to overcome butyrate inhibition. The metabolic model was built using the DRUM framework and consists of 188 reactions and 173 metabolites. After a calibration phase, the model was successfully challenged with data from 122 experiments collected from scientific literature in autotrophic, heterotrophic and mixotrophic conditions. The optimal feeding strategy estimated with the model reduces the time to consume the volatile fatty acids from 16 days to 2 days. The high prediction capability of this model opens new routes for enhancing design and operation in waste valorization using microalgae.

Hierarchical dynamic regulation of Saccharomyces cerevisiae for enhanced lutein biosynthesis

Lutein, as a carotenoid with strong antioxidant capacity and an important component of macular pigment in the retina, has wide applications in pharmaceutical, food, feed, and cosmetics industries. Besides extraction from plant and algae, microbial fermentation using engineered cell factories to produce lutein has emerged as a promising route. However, intra-pathway competition between the lycopene cyclases and the conflict between cell growth and production are two major challenges. In our previous study, de novo synthesis of lutein had been achieved in Saccharomyces cerevisiae by dividing the pathway into two stages (δ-carotene formation and conversion) using temperature as the input signal to realize sequential cyclation of lycopene. However, lutein production was limited to microgram level, which is still too low to meet industrial demand. In this study, a dual-signal hierarchical dynamic regulation system was developed and applied to divide lutein biosynthesis into three stages in response to glucose concentration and culture temperature. By placing the genes involved in δ-carotene formation under the glucose-responsive ADH2 promoter and genes involved in the conversion of δ-carotene to lutein under temperature-responsive GAL promoters, the growth-production conflict and intra-pathway competition were simultaneously resolved. Meanwhile, the rate-limiting lycopene ε-cyclation and carotene hydroxylation reactions were improved by screening for lycopene ε-cyclase with higher activity and fine tuning of the P450 enzymes and their redox partners. Finally, a lutein titer of 19.92 mg/L (4.53 mg/g DCW) was obtained in shake-flask cultures using the engineered yeast strain YLutein-3S-6, which is the highest lutein titer ever reported in heterologous production systems.

Biosynthesis of microalgal lipids, proteins, lutein, and carbohydrates using fish farming wastewater and forest biomass under photoautotrophic and heterotrophic cultivation

Biorefineries enable the circular, sustainable, and economic use of waste resources if value-added products can be recovered from all the generated fractions at a large-scale. In the present studies the comparison and assessment for the production of value-added compounds (e.g., proteins, lutein, and lipids) by the microalga Chlorella sorokiniana grown under photoautotrophic or heterotrophic conditions was performed. Photoautotrophic cultivation generated little biomass and lipids, but abundant proteins (416.66 mg/g_CDW) and lutein (6.40 mg/g_CDW). Heterotrophic conditions using spruce hydrolysate as a carbon source favored biomass (8.71 g/L at C/N 20 and 8.28 g/L at C/N 60) and lipid synthesis (2.79 g/L at C/N 20 and 3.61 g/L at C/N 60) after 72 h of cultivation. Therefore, heterotrophic cultivation of microalgae using spruce hydrolysate instead of glucose offers a suitable biorefinery concept at large-scale for biodiesel-grade lipids production, whereas photoautotrophic bioreactors are recommended for sustainable protein and lutein biosynthesis.

Light Stress after Heterotrophic Cultivation Enhances Lutein and Biofuel Production from a Novel Algal Strain Scenedesmus obliquus ABC-009

Scenedesmus obliquus ABC-009 is a microalgal strain that accumulates large amounts of lutein, particularly when subjected to growth-limiting conditions. Here, the performance of this strain was evaluated for the simultaneous production of lutein and biofuels under three different modes of cultivation - photoautotrophic mode using BG-11 medium with air or 2% CO₂ and heterotrophic mode using YM medium. While it was found that the highest fatty acid methyl ester (FAME) level and lutein content per biomass (%) were achieved in BG-11 medium with CO₂ and air, respectively, heterotrophic cultivation resulted in much higher biomass productivity. While the cell concentrations of the cultures grown under BG-11 and CO₂ were largely similar to those grown in YM medium, the disparity in the biomass yield was largely attributed to the larger cell volume in heterotrophically cultivated cells. Post-cultivation light treatment was found to further enhance the biomass productivity in all three cases and lutein content in heterotrophic conditions. Consequently, the maximum biomass (757.14 ± 20.20 mg/l/d), FAME (92.78 ± 0.08 mg/l/d), and lutein (1.006 ± 0.23 mg/l/d) productivities were obtained under heterotrophic cultivation. Next, large-scale lutein production using microalgae was demonstrated using a 1-ton open raceway pond cultivation system and a low-cost fertilizer (Eco-Sol). The overall biomass yields were similar in both media, while slightly higher lutein content was obtained using the fertilizer owing to the higher nitrogen content.

Mixotrophic Growth of Chlorella sorokiniana on Acetate and Butyrate: Interplay Between Substrate, C:N Ratio and pH

Microalgae can be cultivated on waste dark fermentation effluents containing volatile fatty acids (VFA) such as acetate or butyrate. These VFA can however inhibit microalgae growth at concentrations above 0.5-1 g_C.L^-1. This study used the model strain Chlorella sorokiniana to investigate the effects of acetate or butyrate concentration on biomass growth rates and yields alongside C:N:P ratios and pH control. Decreasing undissociated acid levels by raising the initial pH to 8.0 allowed growth without inhibition up to 5 g_C.L^-1 VFAs. However, VFA concentration strongly affected biomass yields irrespective of pH control or C:N:P ratios. Biomass yields on 1.0 g_C.L^-1 acetate were around 1.3-1.5 g_C.g_C ^-1 but decreased by 26-48% when increasing initial acetate to 2.0 g_C.L^-1. This was also observed for butyrate with yields decreasing up to 25%. This decrease in yield in suggested to be due to the prevalence of heterotrophic metabolism at high organic acid concentration, which reduced the amount of carbon fixed by autotrophy. Finally, the effects of C:N:P on biomass, lipids and carbohydrates production dynamics were assessed using a mixture of both substrates. In nutrient replete conditions, C. sorokiniana accumulated up to 20.5% carbohydrates and 16.4% lipids while nutrient limitation triggered carbohydrates accumulation up to 45.3%.

Enhancement of Phycobiliprotein Accumulation in Thermotolerant Oscillatoria sp. through Media Optimization

Phycobiliproteins (PBPs) are a group of brilliant pigment proteins found in cyanobacteria and red algae; their synthesis and accumulation depend on several factors such as the type of strain employed, nutrient concentration, light intensity, light regimes, and others. This study evaluates the effect of macronutrients (citrate buffer, NaNO₃, K₂HPO₄, MgSO₄, CaCl₂, Na₂CO₃, and EDTA) and the concentration of trace metals in BG-11 media on the accumulation of PBPs in a thermotolerant strain of Oscillatoria sp. The strain was grown in BG-11 media at 28 °C with a light:dark cycle of 12:12 h at 100 μmol m^-2 s^-1 for 15 days, and the effect of nutrients was evaluated using a Plackett-Burman Design followed by optimization using a response surface methodology. Results from the concentration of trace metals show that it can be reduced up to half-strength in its initial concentration without affecting both biomass and PBPs. Results from the Plackett-Burman Design revealed that only NaNO₃, Na₂CO₃, and K₂HPO₄ show a significant increase in PBP production. Optimization employed a central Non-Factorial Response Surface Design with three levels and four factors (3⁴) using NaNO₃, Na₂CO₃, K₂HPO₄, and trace metals as variables, while the other components of BG-11 media (citrate buffer, MgSO₄, CaCl₂, and EDTA) were used in half of their initial concentration. Results from the optimization show that interaction between Na₂CO₃ and K₂HPO₄ highly increased PBPs' concentration, with values of 15.21, 3.95, and 1.89 (% w/w), respectively. These results demonstrate that identifying and adjusting the concentration of critical nutrients can increase the concentration of PBPs up to two times for phycocyanin and allophycocyanin while four times for phycoerythrin. Finally, the reduction in non-key nutrients' concentration will reduce the production costs of colorants at an industrial scale and increase the sustainability of the process.

Pilot-scale cultivation of Chlorella sorokiniana FZU60 with a mixotrophy/photoautotrophy two-stage strategy for efficient lutein production

Chlorella sorokiniana FZU60, a lutein-enriching microalga, was cultivated in 50 L column photobioreactor to evaluate its potential for lutein production. Initial cell concentration, phosphate concentration and aeration rate were optimized, and results showed that optimal conditions of these three parameters were 0.10 g/L, 0.06 g/L and 0.02 vvm (2.5% CO₂), respectively. In addition, a novel two-stage strategy was successfully developed, in which algae were firstly cultivated under fed-batch mixotrophic condition to achieve high biomass concentration, and then shifted to photoautotrophic condition for enhancing lutein accumulation. Moreover, dissolved oxygen was found to be an efficient indicator of acetate depletion in fed-batch stage. The obtained lutein content, production and productivity reached 9.51 mg/g, 33.55 mg/L and 4.67 mg/L/d, respectively, which were greater than those reported in other pilot-scale studies. This proposed strategy provided a cost-effective approach for high-efficient microalgae-based lutein production at pilot-scale, indicating great potential for commercial production.

Growth phase-dependent biochemical composition of green microalgae: Theoretical considerations for biogas production

One of the most efficient and promising technique for biofuel production from microalgae biomass is an anaerobic fermentation. The goal of this work was to investigate changes in the biochemical composition during the long-term cultivation period of 15 green microalgal strains originating from the Baltic Sea. Subsequently, their theoretical methane potential (TMP), which is strictly determined by an algal growth phase and thus physiological state, was established. Based on the full spectrum of changes in the percentage share of lipids, carbohydrates, and proteins in biomass, it was shown that the TMP values differed among strains as well as fluctuated during cultivation. The common trend, i.e., lipids accumulation and proteins breakdown in the late growth phase, was observed for most of the strains; others, however, preferred carbohydrates as storage material. The TMP data obtained herein allows developing a strategy for the design and production of algal biomass biochemically suited for fermentation.

Enhancing Biomass and Lutein Production From Scenedesmus almeriensis: Effect of Carbon Dioxide Concentration and Culture Medium Reuse

The main purpose of this study is to investigate the effects of operative parameters and bioprocess strategies on the photo-autotrophic cultivation of the microalgae Scenedesmus almeriensis for lutein production. S. almeriensis was cultivated in a vertical bubble column photobioreactor (VBC-PBR) in batch mode and the bioactive compounds were extracted by accelerated solvent extraction with ethanol at 67°C and 10 MPa. The cultivation with a volume fraction of CO₂ in the range 0-3.0%v/v showed that the highest biomass and lutein concentrations - 3.7 g/L and 5.71 mg/g, respectively - were measured at the highest CO₂ concentration and using fresh growth medium. Recycling the cultivation medium from harvested microalgae resulted in decreased biomass and lutein content. The nutrient chemical composition analysis showed the highest consumption rates for nitrogen and phosphorus, with values higher than 80%, while sulfate and chloride were less consumed.

Consolidated bioprocessing of wastewater cocktail in an algal biorefinery for enhanced biomass, lipid and lutein production coupled with efficient CO2 capture: An advanced optimization approach

We present a holistic approach in establishing a successful green integrated bio-refinery system with improved biomass, lipid and lutein productivity, while remediating wastewater and sequestering CO₂ with potential biodiesel and healthcare applications. To achieve this we evaluated the effect of four process parameters: CO₂% supply; acetate concentration; poultry litter waste (PLW) concentration; and light intensity on cultivation of Chlorella minutissma following the Taguchi's design of experimental technique. A four factors, three levels orthogonal array was adopted to cultivate Chlorella minutissma in specially developed waste water medium. Effect of the process parameters on biomass productivity, CO₂ fixation rate, lipid content, lutein productivity and bioremediation capacity were determined. Results obtained from individual parametric combinations and Signal/Noise (S/N) ratio responses indicated S3 (5% CO₂, 100 mg L^-1 of acetate, 10 g L^-1 of poultry litter, and 15, 000 lux of light intensity) combination as the optimum cultivation condition. Following the S3 combination a significant enhancement in biomass productivity (292 mg L^-1 d^-1) with exceedingly high CO₂ fixation rate and photosynthetic efficiency (51.51 g L^-1 d^-1 of CO₂; P.E: 15.81%) was achieved. A maximum of 169.29 mg L^-1 d^-1 of lipid with a balanced distribution of saturated and unsaturated fatty acids conformed to the international standard for biodiesel was achieved. Additionally, 7.21 mg L^-1 d^-1 of lutein productivity was also accomplished within 7 day of cultivation, while remediating up to 93-90% of nitrogenous and phosphate substrates. Statistically, the results reinforced our findings with the S/N responses and experimental observations for a particular property.

Exploring biostimulation of plant hormones and nitrate supplement to effectively enhance biomass growth and lutein production with thermo-tolerant Desmodesmus sp. F51

In this study, the interactive effect of plant hormone-salicylic acid and succinic acid on biomass growth, lutein content, and productivity of Desmodesmus sp. F51 were investigated. The results demonstrated that the synergistic action of salicylic acid and succinic acid could effectively enhance the assimilation of nitrate and significantly improve lutein production. The maximal lutein content 7.01 mg/g and productivity 5.11 mg/L/d could be obtained with a supplement of 100 µM salicylic acid and 2.5 mM succinic acid in batch culture. Furthermore, operation strategy of nitrate fed-batch coupled with supplementation for succinic acid and salicylic acid resulted in further enhancement of lutein content and productivity by 7.50 mg/g and 5.78 mg/L/d, respectively. The performance is better than most of the previously reported values.

Effect of light quality on growth rate, carbohydrate accumulation, fatty acid profile and lutein biosynthesis of Chlorella sp. AE10

Microalgae are feedstocks for multiple product development based on algal biorefinery concept. The effects of light quality (white, red and blue light emitting diodes) and macro-element starvations on Chlorella sp. AE10 were investigated under 20% CO₂ and 850 µmol m^-2 d^-1. Nitrogen and phosphorus starvations had negative effects on its growth rate. The biomass productivities were decreased from day 1 and the highest one was 1.90 g L^-1 d^-1 under white light conditions. Phosphorus starvation promoted carbohydrate accumulation under three LED light sources conditions and the highest carbohydrate content was 75.9% using red light. Blue light increased lutein content to 9.58 mg g^-1. The content of saturated fatty acids was significantly increased from 37.51% under blue light and full culture medium conditions to 77.44% under blue light and nitrogen starvation conditions. Chlorella sp. AE10 was a good candidate for carbohydrate and lutein productions.

Bioprocess operation strategies with mixotrophy/photoinduction to enhance lutein production of microalga Chlorella sorokiniana FZU60

This study isolated and identified the lutein-enriching microalga Chlorella sorokiniana FZU60. Different types of media and concentrations of sodium acetate and nitrate were evaluated to improve mixotrophic growth and lutein production. Highest lutein content, production, and productivity were obtained in BG11 medium with 1 g/L acetate and 0.75 g/L nitrate. Additionally, pulse feeding with 1 g/L acetate every 48 h led to the alternation between mixotrophy and photoinduction, resulting in a lutein production of 33.6 mg/L. Most notably, excellent lutein content (9.57 mg/g) and productivity (11.57 mg/L/d) were obtained using a new multi-operation integrated strategy, and the achieved levels exceed those reported in most related studies. This work demonstrates the synergistic integration of simple and effective strategies for the enhancement of lutein production in the indigenous microalga C. sorokiniana FZU60 and provides new insight into the highly efficient microalgae-based lutein production.

Bench-Scale Cultivation of Microalgae Scenedesmus almeriensis for CO2 Capture and Lutein Production

In this study, Scenedesmus almeriensis as green microalga was cultivated on bench-scale for carbon dioxide (CO2) capture and lutein production. The autotrophic cultivation of S. almeriensis was carried out by using a vertical bubble column photo-bioreactor (VBC-PBR) with a continuous flow of a gaseous mixture of oxygen (O2), nitrogen (N2), and CO2, the latter in content of 0.0–3.0 %v/v. The liquid phase was batch. S. almeriensis growth was optimized. In addition, lutein extraction was carried out by using accelerated solvent extraction with ethanol as Generally Recognized as Safe (GRAS) solvent at 67 °C and 10 MPa. Upon optimization of CO2 concentration, the maximum biomass productivity, equal to 129.24 mg·L−1·d−1, was achieved during the cultivation by using a content of CO2 equal to 3.0 %v/v and it allowed to obtain a lutein content of 8.54 mg·g−1, which was 5.6-fold higher in comparison to the analogous process carried out without CO2 addition. The ion chemical analysis in the growth medium showed that by gradually increasing CO2 content, the nutrient consumption during the growth phase also increased. This study may be of potential interest for lutein extraction at industrial scale, since it is focused on pigment production from a natural source with a concomitantly CO2 capture.

A highly efficient two-stage cultivation strategy for lutein production using heterotrophic culture of Chlorella sorokiniana MB-1-M12

A heterotrophic mutant of Chlorella sorokiniana MB-1-M12 was evaluated for its ability to produce lutein using organic carbon and nitrogen sources and without light irradiation. In batch fermentation, the maximal lutein content (3.67 mg lutein/g biomass) and productivity (2.84 mg/L/d) could be obtained when cultivated in BG-11 medium with 7.5 g/L glucose, 0.75 g/L urea, pH 7.5 and a C/N ratio of 10. A novel two-stage cultivation strategy that integrates fed-batch and semi-batch operations was applied to enhance the lutein production performance. When growing MB-1-M12 strain in a 5L fermenter using the optimal operation strategies, the maximum biomass concentration, biomass productivity, lutein content and lutein productivity could reach 25 g/L, 4.88 mg/L/d, 5.88 mg/g and 16.2 mg/L/d, respectively. This high lutein productivity could significantly reduce the cultivation time and the associated costs, indicating the potential of using MB-1-M12 strain for heterotrophic lutein production in commercial scale.