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24 Sep 2021 --- Dutch producer Duplaco is scaling up its chlorella capacity with sights set on becoming Europe’s largest algae producer. Increased production comes amid a barrage of supply and quality challenges from Southeast Asia, where much of the “super food” for plant-based meat and supplements comes from.  “The prices of container shipments from Southeast Asia have increased tenfold,” Marcel Oogink, founder and managing director of Duplaco tells FoodIngredientsFirst.

“Many companies are facing issues with the reliability of supplies, fluctuating qualities and contamination, with the latest issue being ethylene-oxide.” 

Production in Europe bypasses transparency and supply issues associated with importing algae from Southeast Asia. Duplaco’s customer list already includes major manufacturers of supplements that explicitly promote their products, referring to their cultivation within the EU.

Marcel Oogink, founder and managing director of Duplaco. Sustainable upscaling  The company’s expansion follows its move from a pilot plant in Hengelo to commercial production in Oldenzaal, the Netherlands. 

The cultivation is independent of sunlight, weather and climate conditions, guaranteeing consistent quality. It is also more cost-effective because a high volume of chlorella can be produced with a small footprint. 

Moreover, the company can feed the algae with sidestream ingredients, such as molasses, a by-product of sugar production. 

“We have already expanded our production from 15 tons to 200 to 300 tons per year. We aim to increase our capacity to 1,500 tons per year in the next three to five years,” explains Oogink.

“With 1,500 tons, we would make about 12.5% of the current global chlorella capacity.”

Packed with nutrition Within the Netherlands, Duplaco’s chlorella is used as a key ingredient in “cult brand” The Dutch Weed Burger, which was recently acquired by Livekindly Collective.

Duplaco’s chlorella contains a high percentage of protein (40%) as well as fiber, unsaturated fatty acids and more than 40 different vitamins, minerals, antioxidants and all amino acids. 

“As a functional ingredient, chlorella optimizes the nutritional content of food such as plant-based meat, fish and dairy alternatives, pasta, smoothies or baked goods,” says Oogink. 

Two grams of Duplaco’s Chlorella Gold has about 0.24 μg of vitamin B12 (cobalamin), making it an “interesting” plant-based source of vitamin B12 in plant-based foods and beverages.

When working with fresh chlorella, the ingredient can “easily” make up a substantial amount of a plant-based meat alternative, up to 30%. 

Duplaco’s chlorella is as a key ingredient in The Dutch Weed Burger. Color considerations Based on the food or beverage being formulated, different types of chlorella can be used. 

“In our own research and development center, we adapt the nutritional profile of the algae to the individual customer requirements, and we can also lower the green pigments using breeding techniques.”

Considering that some customers may prefer chlorella with chlorophyll and some without, the company is also working on new varieties that are free of green coloring. 

“It took us only a few months to develop the current yellow-gold chlorella, which gives you an indication of the required time [to remove chlorophyll via breeding].”

While breeding is a slower process, Oogink explains that Duplaco wants to avoid the practice of extracting green pigments through chemical treatment, a technique that other algae producers use. 

Based on customer feedback, Duplaco says its green chlorella can provide a umami, nutty taste. The yellow-gold version, meanwhile, has a neutral taste, making it easy to blend into different kinds of products without a negative impact on the taste profile.

Dietary supplement applications With its high nutritional profile, it is also being used as a dietary supplement. Harvested chlorella is spray dried and pressed into tablets. The company recommends 0.1 g/kg body weight per day for usage as a supplement. 

“We grow high purity Chlorella pyrenoidosa, which includes the vitamins A, C, D, E, K and B vitamins 1, 2, 3, 5, 6. It also contains the minerals potassium, magnesium, calcium, phosphorus, iron, zinc and manganese,” Oogink affirms.

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