Microalgae are a
promising source of starch with the potential
to reduce land and water footprints as compared to terrestrial plants.
However, so far, there are no specific downstream processes to recover
microalgal starch. In this work, the development of a lab-scale biorefinery
to produce microalgal starch is described. Guidelines are provided
on how to set up microalgae cultivation, attaining until 37% starch
content and 0.48 g L–1 d–1 starch
productivity in 500 mL lab-scale photobioreactors. Cell lysis by ultrasonication
in water and ethanol was studied, obtaining better disruption rates
at a lower temperature (≈30 °C) in water. The refinery
of the lysate was studied by comparing the conventional Percoll protocol
with more potentially scalable methods: aqueous two-phase systems
(ATPSs) and ethanol extraction. Ethanol allowed attainment of the
best results, separating quantitatively lipids, with reduced pigment
degradation, by ensuring higher starch recovery (91%) and starch content
(57%) in the refined pellet. Finally, refined starch was used to produce
a plastic film that showed mechanical properties comparable to those
obtained by using corn starch. This study provides preliminary evidence
that microalgal starch could replace conventional starch sources in
the biobased industry, possibly with reduced environmental impacts.