SCALE

Supplying bioactives Compounds from micro-Algae to foster a bLue futurE

Project details

Type of project: Innovation Action – Flagship
Project focus: Food, feed & cosmetics
Feedstock origin: Aquatic
Feedstock type: Micro/macro algae

Project period: 1 June 2021 - 31 May 2025
Status: Completed
CBE JU Contribution: € 14 304 045,22
Call identifier: H2020-BBI-JTI-2020

Summary

The current food system is seriously challenged by evolving consumers needs and by the rapid world population growth, which could peak to 9.7 billion people in 2060. To provide food system with high nutritional value ingredients, it becomes of paramount important to harness the potential of the oceans in an environmentally responsible manner. Microalgae are a highly promising source of aquatic biomasses and find applications in a wide range of fields, including nutrition and well-being. Currently, no large-scale industrial production site provides access to the exceptional biodiversity of microalgae in an efficient way. Only a few species are produced globally with dedicated production sites. For instance, 70% of the market is currently represented by Spirulina and Chlorella.

The SCALE project addressed this challenge by developing a first-of-its-kind industrial flagship plant for the production of high-value ingredients derived from underexploited microalgae species. The facility was designed to supply ingredients for the food, food supplements, feed and cosmetics sectors through economically viable and environmentally responsible processes.

To achieve this, SCALE brought together 11 key European and international partners from five countries, covering the entire value chain, from microalgae cultivation and the extraction of bioactive compounds to their incorporation into end products. The consortium also worked on improving the energy efficiency of the production process, including through innovative LED-based lighting solutions adapted to the specific requirements of microalgae cultivation and more environmentally friendly approaches to meeting the facility's energy and thermal needs.

The project demonstrated the versatility of microalgae-derived compounds across several industrial applications. In cosmetics, these ingredients were explored as natural alternatives to synthetic components, including in collaboration with Chanel Parfums Beauté, with potential skin-protective and anti-ageing properties. In the food and wellbeing sectors, microalgae-derived ingredients offered potential applications in food supplements supporting cognition, weight management and immunity. Their nutritional composition, particularly their protein, vitamin and mineral content, also highlighted their potential as alternative food ingredients.

Beyond product development, SCALE contributed to the wider development of the European bioeconomy. Its controlled cultivation methods avoided disruption to natural aquatic ecosystems, while its algae-derived feed ingredients offered opportunities to support more sustainable aquaculture and reduce reliance on wild fish stocks. The project also targeted a reduction in greenhouse gas emissions of at least 20%, alongside opportunities for employment and skills development in coastal and rural communities.

More information

CBE JU-funded SCALE flagship biorefinery in Baillargues, France

Environmental sustainability: reduce dependence on fossil-based resources by developing sustainable alternatives to animal-derived products, particularly in the food and food supplements sectors. The project also aims to reduce greenhouse gas emissions through microalgae cultivation, which does not generate direct GHG emissions and can act as a CO₂ sink, while contributing to the EU’s climate objectives and supporting the preservation and enhancement of marine biodiversity.
Economic growth and competitiveness: strengthen the European algae production sector and improve its competitiveness by demonstrating the viability of industrial-scale microalgae production. The flagship biorefinery aims to create approximately 50–60 direct jobs and 190 indirect jobs across the food, food supplements, feed, cosmetics, construction and engineering sectors, with the potential for replication at additional sites.
Regional development and employment: support sustainable local development in Occitania by attracting investment and creating new employment opportunities in a rural area, thereby strengthening the regional economy.
Efficient resource and land use: minimise pressure on land resources by adopting microalgae cultivation methods that are approximately ten times more eco-efficient than conventional cultivation approaches, enabling more sustainable biomass production.

Results

Industrial-scale microalgae biorefinery: successfully established a first-of-its-kind, fully integrated industrial microalgae production facility in Baillargues, near Montpellier, France. The 5,000 m² flagship plant was equipped with proprietary large-scale photobioreactors, enabling the industrial production of ingredients from a wider diversity of microalgae species.
Large-scale production of bioactive ingredients: achieved the capacity to produce more than 100 tonnes of bioactive ingredients annually, demonstrating the potential of microalgae as a reliable source of high-value natural ingredients for different industries.
Development and validation of innovative ingredients: developed and validated a portfolio of innovative microalgae-derived ingredients for nutrition, food supplements, animal feed and cosmetics. These included products such as PhaeOptim™, BrainPhyt™, GamePhyt™, ZenGut™, DunaPure™ and Luteana™, among others.
Improved production efficiency and sustainability: optimised the cultivation and processing technologies through advanced photobioreactors, improved LED lighting systems and more efficient extraction processes. The facility also incorporated renewable energy through solar panels, advanced wastewater treatment and improved resource management. Production avoided the use of genetically modified organisms and pesticides, while making use of CO₂.
Progress towards industrial and commercial uptake: achieved important progress in bringing microalgae-derived ingredients closer to commercial application. The facility obtained FSSC 22000 food safety certification and COSMOS approval for cosmetic applications. Industrial partners also began testing the ingredients, while the project contributed to local economic development and created 31 direct jobs at Microphyt during its implementation.

Impacts

Cross-sectoral collaboration: established five new cross-sectoral interconnections within the bio-based economy, linking the microalgae industry with the food, food supplements, animal feed, cosmetics and technology sectors.
Development of bio-based value chains: created four new bio-based value chains, covering the entire process from raw material supply to the development of final products in the food, food supplements, animal feed and cosmetics sectors.
Development of innovative ingredients: supplied and tested eight new microalgae-based ingredients for each of the target sectors, introducing new active compounds with potential applications in consumer products.
Contribution to the European bioeconomy: strengthened the portfolio of BBI JU flagship projects and contributed to its broader mission of advancing the European bio-based economy through industrial innovation, cross-sectoral collaboration and the development of sustainable value chains.