Integrated Downstream Processing for Recovery of β-carotene and Lutein–Enriched Products from Dunaliella Biomass

This technology offers a highly efficient, process-intensified approach for extracting β-carotene and lutein from Dunaliella biomass by integrating cell disruption, extraction, and in situ formulation into a single-step operation. Unlike conventional multi-stage processes, it significantly reduces processing time (50–60 minutes), energy consumption, and solvent usage, as it operates under mild, room-temperature conditions. The use of a biocompatible extractant ensures product safety and suitability for nutraceutical applications. The process delivers high-purity products (~75% β-carotene and ~70% lutein) while minimizing downstream complexity and operational costs. This translates to lower capital and operating expenses, improved scalability, and faster throughput, making it highly attractive for industrial adoption. Overall, the technology enhances economic viability and sustainability, offering a competitive advantage for commercial production of high-value algal β-carotene and lutein

• Nutraceutical formulations
• Eye & skin health
• Immune support
• Food colorants
• Cosmetic formulations involving natural color & antioxidants

• Executes all three essential unit operations–cell disruption, extraction & formulation simultaneously in a single reaction vessel.
• Room temperature conditions (27–30°C) with less time (50–60 min).
• No specialized equipment or device required.
• Stability of the carotenoids was shown potential for 4 weeks (94%) at room temperature (27–30°C).
• Preliminary economic analysis indicates that this downstream technology enables processing of 1 kg biomass at ~four times lower cost compared to existing solvent extraction methods.