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Lutein, a yellow xanthophyll carotenoid, is increasingly recognized for its nutraceutical benefits, particularly in protecting the retina’s macula from age-related degeneration. Microalgae are a promising source of lutein, which can be a primary product or a coproduct in biorefineries. Certain microalgae exhibit lutein levels (up to 1.7%) surpassing those of common dietary sources like kale, spinach, and egg yolk (approximately 0.7–0.9%). Predominantly associated with photosystem II’s light-harvesting complex, lutein is crucial in photosynthesis and cellular defense. However, being quantitatively minor among cellular constituents, lutein necessitates specialized processing for efficient extraction. Although ubiquitous in microalgae, it is not as easily inducible as β-carotene and astaxanthin in Dunaliella salina and Haematococcus pluvialis, respectively. Currently, microalgal lutein production predominantly occurs at the bench scale, presenting challenges in scaling up. Factors like culture medium significantly influence biomass and lutein yields in industrial production, while downstream processing requires cost-effective, food-grade solvent extraction techniques. This review delves into contemporary methods and innovative progress in microalgal lutein production, emphasizing industrial-scale processes from biomass cultivation to final product formulation. A conceptual industrial process proposed in this review shows that two 10 m3 photobioreactors could produce 108 kg dry mass for Chlorella minutissima, which can be processed into approximately 616 g of lutein extract, or over 6000 capsules of finished nutraceutical daily. Despite lutein production via microalgae being in nascent stages at large scales, existing research provides a solid foundation for well-informed scale-up endeavors.

Cassava processing wastewater (CPW) is a highly polluting, liquid residue of cassava processing, usually discarded or treated anaerobically. However, it can serve as a low-cost culture medium for microalgae. After a preliminary evaluation of the growth of 10 microalgal strains in diluted CPW, the microalgae Haematococcus pluvialis SAG 34−1b and Neochloris (Ettlia) oleoabundans UTEX 1185 were selected for cultivation in CPW without a supply of additional nutrients and evaluated for their growth, lipid production, and nutrients removal. Maximal biomass concentrations of 1.79 g·L−1 for H. pluvialis and 3.18 g·L−1 for N. oleoabundans were achieved with 25% CPW medium on the 13th day of growth. The algae H. pluvialis and N. oleoabundans removed 60.80 and 69.16% of the chemical oxygen demand, 51.06 and 58.19% of total nitrate, and 54.68 and 69.84% of phosphate, respectively. On average, lipid productivities reached 0.018 and 0.041 g·L−1 day−1 for H. pluvialis and N. oleoabundans, respectively. Therefore, cultivating these microalgae in diluted CPW is a promising treatment for cassava wastewater with simultaneous valuable biomass production.

Recycling bioresources is the only way to sustainably meet a growing world population’s food and energy needs. One of the ways to do so is by using agro-industry wastewater to cultivate microalgae. While the industrial production of microalgae requires large volumes of water, existing agro-industry processes generate large volumes of wastewater with eutrophicating nutrients and organic carbon that must be removed before recycling the water back into the environment. Coupling these two processes can benefit the flourishing microalgal industry, which requires water, and the agro-industry, which could gain extra revenue by converting a waste stream into a bioproduct. Microalgal biomass can be used to produce energy, nutritional biomass, and specialty products. However, there are challenges to establishing stable and circular processes, from microalgae selection and adaptation to pretreating and reclaiming energy from residues. This review discusses the potential of agro-industry residues for microalgal production, with a particular interest in the composition and the use of important primary (raw) and secondary (digestate) effluents generated in large volumes: sugarcane vinasse, palm oil mill effluent, cassava processing waster, abattoir wastewater, dairy processing wastewater, and aquaculture wastewater. It also overviews recent examples of microalgae production in residues and aspects of process integration and possible products, avoiding xenobiotics and heavy metal recycling. As virtually all agro-industries have boilers emitting CO2 that microalgae can use, and many industries could benefit from anaerobic digestion to reclaim energy from the effluents before microalgal cultivation, the use of gaseous effluents is also discussed in the text.

The antioxidant and food pigment astaxanthin (AX) can be produced by several microorganisms, in auto- or heterotrophic conditions. Regardless of the organism, AX concentrations in culture media are low, typically about 10–40 mg/L. Therefore, large amounts of nutrients and water are necessary to prepare culture media. Using low-cost substrates such as agro-industrial solid and liquid wastes is desirable for cost reduction. This opens up the opportunity of coupling AX production to other existing processes, taking advantage of available residues or co-products in a biorefinery approach. Indeed, the scientific literature shows that many attempts are being made to produce AX from residues. However, this brings challenges regarding raw material variability, process conditions, product titers, and downstream processing. This text overviews nutritional requirements and suitable culture media for producing AX-rich biomass: production and productivity ranges, residue pretreatment, and how the selected microorganism and culture media combinations affect further biomass production and quality. State-of-the-art technology indicates that, while H. pluvialis will remain an important source of AX, X. dendrorhous may be used in novel processes using residues.