<I>Dunaliella Salina</I>

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<I>Dunaliella Salina</I> BULLETIN OF MARINE SCIENCE, 47(1): 244-252, 1990 COMMERCIAL PRODUCTION OF (3-CAROTENE BY DUNALIELLA SALINA IN OPEN PONDS Lesley J. Borowitzka and Michael A. Borowitzka ABSTRACT The halophilic green unicellular alga Dunaliella salina is an important commercial source of }3-carotene. The algal culture process used in Western Australia is described and compared with the process used at other sites, and the advantages and disadvantages of these processes are reviewed. Harvesting" extraction and formulation are also discussed. jJ-Carotene is a C40 carotenoid found in all green plants where it is localized in the chloroplast. Its main commercial use is in the food industry where it is used as a coloring agent in margarine, baked goods and other food products (KHiui, 1982). {3-Carotene has also been shown to be a good scavenger of free radicals and other reactive species (Krinsky, 1979) and appears to have a role as a pro- tective agent against cancer. In recent years, much clinical evidence has accu- mulated on this potential cancer protective activity of jJ-carotene (Ibrahim et a1., 1977; Mathews-Roth, 1982; Schwartz et a1., 1986) and, as further evidence ac- cumulates, this should develop into an additional major application of jJ-carotene. At present, most of the commercially available jJ-carotene (all-trans jJ-carotene) is produced by synthetic means (Isler, 1979) and sells for about $AUS 600·kg-1 (=$U.S. 500). In recent years, however, there has developed an increasing market demand for natural jJ-carotene. The green volvocalean alga Dunaliella salina Teodoresco has the highest cell content of jJ-carotene of any organism, with concentrations of up to 14% of dry weight having been reported (Mil'ko, 1963; Aasen et al., 1969). Massyuk (1966) first proposed that this alga might be a suitable natural source of jJ-carotene and over several years carried out trials on Dunaliella culture in the Ukraine (Massyuk and Abdulla, 1969). In the 1970's work on jJ-carotene production using D. salina commenced in several other parts of the world, and in 1986 commercial pro- duction commenced in Australia, the USA and in Israel (Borowitzka and Boro- witzka, 1988a). In this paper we describe several aspects of the commercial jJ-carotene production process using D. salina and point out some of the critical steps in this process. DUNALIELLA CuLTURE PROCESS Dunaliella salina is the most salt-tolerant eukaryotic alga known and can grow in media saturated (> 30% w/v) with NaCl (Borowitzka and Brown, 1979). D. salina is also very tolerant of high temperatures and high photon flux densities (Borowitzka and Borowitzka, 1988a). Development of mass culture conditions has required the optimization of growth conditions so as to produce the maximum amount of jJ-carotene per unit time and culture volume. This has been complicated by the fact that the conditions leading to maximum cell growth are different from those leading to maximum accumulation of ,a-carotene in the cell. For example, D. salina has an optimum salinity for growth of about 18-21 % NaCl, whereas the maximum jJ-carotene content is reached at a salinity of> 27% NaCl (Borowitzka et al., 1984). Similarly, 244 BOROWITZKA AND BOROWITZKA: BETA CAROTENE PRODUCTION 245 l1-caroteneaccumulation is highest under nitrogen-limiting conditions where growth is reduced. Based on these and other observations, early workers proposed a two-stage process for growth (Chen and Chi, 1981), consisting of a growth stage at about 18% NaCl and with sufficient nitrogen to attain the maximum biomass, followed by a carotenoid-accumulating stage at a salinity of about 27% NaCI and N-limiting conditions (Borowitzka et al., 1986). However, early field studies and economic analyses soon showed that such a process was not feasible for several reasons: (1) At the lower salnities, predation by protozoa, especially by Cladotricha sigmoidea and Heteroamoeba sp. often led to a rapid decimation of the algal biomass in the ponds (Post et al., 1983; Borowitzka et al., 1986); (2) At the lower salinities the non-carotenogenic Dunaliella species, D. viridis Teodoresco, which always co- occurs with D. salina in open-air ponds, could outgrow D. salina (Borowitzka et al., 1986; Moulton et al., 1987b); and (3) The two-step process is labor intensive and requires a greater pond area and is thus too expensive. As a result of these considerations, a semi-continuous process, operating at an intermediate salinity was finally chosen (Borowitzka et al., 1986; Moulton et al., 1987a). The salinity was optimized for maximum l1-carotene production per unit time in the pond. Nutrient concentrations were also optimized. The major nutrients added to ponds are nitrogen, phosphate and a chelated form of iron. Depending on the brine used, trace elements may also have to be added (Ben Amotz et al., 1982; Ben Amotz and Avron, 1983; Borowitzka and Borowitzka, 1988a, 1988b). The Ca:Mg and Cl-:S04 - ratio of the brines used in culture may also affect growth and carotenogenesis (Ben Amotz and Avron, 1983) and must be considered when selecting the source of brines for growth. Another consideration for commercial mass culture is pond design. For ex- ample, Israeli and U.S. operations use variants of the paddle-wheel "raceway" ponds of the design originally developed by Oswald (1988), whereas the Australian operations use large unstirred ponds (Borowitzka and Borowitzka, 1988a). The large unstirred ponds (unstirred other than by wind mixing) used by Western Biotechnology Ltd. at their production plant at Hutt Lagoon, Western Australia, have a lower algal biomass than would be achieved if raceway-type ponds were used; however, this lower biomass is offset by the greatly reduced cost of pond construction and maintenance. The "natural" ponds used in Australia also have another advantage over the lined ponds used elsewhere. Plastic lined ponds almost always have problems with the build-up of gas bubbles under the plastic liner and these must be overcome by effectively "sterilizing" the soil under the liner. Un- lined earthen ponds do not have this problem, although turbidity may be greater. In all cases pond depth is maintained at about 20 em for maximum light pene- tration. A final consideration for open air production of D. salina is the siting of the production facility. Since open air ponds are subjected to the vagaries of the weather, the plant location must have a suitable climate. An optimum site, such as Hutt Lagoon in Western Australia, has a long, hot, dry summer and is situated at or near a suitable source of brines. The location should also be remote from possible pOllution produced by industrial or agricultural activities (i.e., pesticides or heavy metals) as the final product produced will be used in human food. The land should also be fairly flat to minimize pond construction costs. Large open-air ponds have a number offeatures which differ from those of well- mixed large-scale cultures in closed systems because of (a) the importance of climate (wind, rain, temperature), (b) contamination, (c) the heterogeneous dis- tribution of organisms in the pond, and (d) differences in scale-up (Borowitzka et 246 BULLETIN OF MARINE SCIENCE, VOL. 47, NO. I, 1990 a 4 E -0 8 -~ Q. -Q) 12 0 16 20 ____________ 1 I I I I I I·J 0.1 1 10 100 16 20 28 Cell Number(x 104 cells. ml-1) Salinity (% brix) Figure 1. Distribution of Dunaliella salina (.) and D. viridis (0) with depth in a 100 m2 pond at Hutt Lagoon following rain. The salinity profile is shown at the right. al., 1984; 1986; Borowitzka and Borowitzka, 1988a; Moulton et al., 1987). We have found that scale-up oflarge open-air ponds must proceed in a series of steps, each representing a factor of 10 increase, to be able to cope with changes in both biological and engineering parameters. At Hutt Lagoon the initial outdoor experiments were carried out in plastic ponds of several hundred liters capacity to test the effects of local climatic con- ditions on cultures. These were then scaled-up to earth-walled ponds constructed on the lake bed ofHutt Lagoon, having an area of 100 m2 (approx. 20,000 liter). Smaller ponds were abandoned (1) due to the high wall area to pond volume ratio which resulted in high rates ofleakage; (2) a tendency to lose pond holding capacity due to erosion of the banks; (3) loss of algae due to windrowing of the cells; and, (3) reduced salinity, erosion of the banks and increased turbidity resulting from rainwater runoff. All of these disadvantages were reduced in larger ponds. Scale-up at Hutt Lagoon progressed from the 100 m2 ponds to 250 m2 (50,000 liters) and 600 m2 (120,000 liters). These ponds were used to explore the effects of nutrient addition, pond depth, salinity and climate on growth and caroteno- genesis. Several different pond management regimes were tested. Before the final production plant was designed, further experiments were carried out in 0.5-ha ponds (i.e., 1I1Oth the size of the proposed production ponds) to provide data for accurate economic analysis of the process. Scale-up from these to the 5-ha production-ponds then proceeded smoothly. It is difficult to sample large open-air ponds at all stages (experimental, pilot and production) of pond management. In large ponds there is some patchiness in the distribution of D. salina due to the natural taxes of the algae (Moulton et al., 1987b; Wangersky and Maass, 1988). Also, differential heating of the surface BOROWITZKA AND BOROWITZKA: BETA CAROTENE PRODUCTION 247 layers of the pond, stratification of lower salinity water on the pond surface after rainfall, and variable mixing due to wind and convection results in heterogeneous algal distribution.
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