Operations & process excellence
A 25-acre coastal production site with automated cultivation, cell-safe harvesting and freeze-drying, built for contaminant-free, food-grade biomass.
Nellore: ideal conditions for Dunaliella
Our facility sits in Allur Mandal, Nellore district, on India’s East Coast. Year-round tropical sunshine and abundant saline water make it ideal for cultivating Dunaliella salina.
At current capacity, we aim to produce 10 metric tons of high beta-carotene dry Dunaliella salina biomass per year, and we plan to expand capacity in line with customer demand. Our approach uses coastal land and solar energy to keep the carbon footprint low.
- Patented R&D: our team holds Indian Patent No. 545438 for one of its Dunaliella salina cultivation inventions (view patent); commercial production uses our 100% vegan process
- Automated cultivation, harvesting and pasteurisation for contaminant-free biomass
- Novel photobioreactors for scale-up
- 100% sustainable and organic process, with water recycled back into production
From strain to sealed pack
We preserve the natural photosynthetic process that microalgae have used for billions of years, and enhance it with advanced technology and strict protocols.
1 · Upstream preparation
Strains and inoculum are grown in the lab to produce young, high-density cultures. Water is physically and chemically treated, nutrients are precisely dosed, and CO₂ supply is managed to boost photosynthesis.
2 · Upstream cultivation
Intensive, controlled cultivation in raceway ponds and photobioreactors. pH, temperature, nutrients, dissolved oxygen and CO₂ injection are all monitored for maximum productivity.
3 · Ultrafiltration
A 0.025 µm ultrafiltration system concentrates the culture from 0.05% to 15% while retaining 100% of algal cells. The clean water is recycled back into production.
4 · Spiral-plate centrifugation
Over 95% separation efficiency, giving 25–35% solids without damaging delicate Dunaliella cells. It needs no chemicals, uses little energy and yields 1.5–2× more dry weight than traditional centrifuges.
5 · Freeze-drying
Lyophilisation removes water by sublimation at low temperature, preserving carotenoids, colour and nutritional value. It loses far less carotenoid during storage than tray drying.
6 · Pulverising & vacuum packing
Dried biomass is pulverised into a fine powder, quality checked, then vacuum-sealed in specialised bags in a range of sizes.
Inside the facility
