Sustainable Omega-3 Lipid Production from Agro-Industrial By-Products Using Thraustochytrids: Enabling Process Development, Optimization, and Scale-Up.

Thraustochytrids are emerging as a valuable biomass source for high-quality omega-3 polyunsaturated fatty acids (PUFAs), crucial for both human and animal nutrition. This research focuses on cultivating SR21 using cost-effective agro-industrial by-products, namely sugarcane molasses (SCM), corn steep liquor (CSL), and residual yeast cream (RYC), to optimize biomass and lipid production through a comprehensive multistep bioprocess. The study involved optimization experiments in shake flasks and stirred-tank bioreactors, where we evaluated biomass, lipid content, and DHA yields. Shake flask optimization resulted in significant enhancements in biomass, lipid content, and lipid production by factors of 1.12, 1.72, and 1.92, respectively. In a 10 L stirred-tank bioreactor, biomass surged to 39.29 g/L, lipid concentration increased to 14.98 g/L, and DHA levels reached an impressive 32.83%. The optimal concentrations identified were 66 g/L of SCM, 24.5 g/L of CSL, and 6 g/L of RYC, achieving a desirability index of 0.87, aimed at maximizing biomass and lipid production. This study shows that agro-industrial by-products can be effective and low-cost substrates for producing lipids using thraustochytrids, offering a sustainable option for omega-3 PUFA production. The findings support future improvements in bioprocesses and potential uses of thraustochytrid biomass in food fortification, dietary supplements, nutraceuticals, and as vegan omega-3 sources.