Microalgal Flour

Abstract

Compositions of microalgae-derived flour are disclosed from multiple genera, species, and strains of edible microalgae. Microalgae used in the invention are free of algal toxins and contain varying levels of primarily monounsaturated triglyceride oil. Flours disclosed herein are formulated as free flowing blendable powders, mixed food ingredients, oxidation stabilized, homogenized and micronized, and combinations therein. Flours disclosed herein also form self stabilizing emulsions in slurries with manageable viscosities. Innovative methods of formulating flours and incorporating them into food compositions are also disclosed. The invention also comprises flours with significant digestible protein and unique dietary fiber content and associated water binding, texturizing, and healthy oil delivery attributes. Novel methods of oil and fat replacement using flours of the invention are also disclosed. Flours of the invention can be manufactured from edible and inedible heterotrophic fermentation feedstocks, including corn starch, sugar cane, glycerol, and depolymerized cellulose.

1 . A microalgal flour comprising a homogenate of microalgal biomass containing predominantly or completely lysed cells in the form of a powder comprising at least 16% by dry weight triglyceride oil. 
     
     
         2 . The microalgal flour of  claim 1 , wherein the average size of particles in the powder is less than 100 μm. 
     
     
         3 . The microalgal flour of  claim 1 , wherein the average size of particles in the powder is 1-15 μm. 
     
     
         4 . The microalgal flour of  claim 1 , wherein the powder is formed by micronizing microalgal biomass to form an emulsion and drying the emulsion. 
     
     
         5 . The microalgal flour of  claim 1 , having a moisture content of 10% or less or 5% or less by weight. 
     
     
         6 . The microalgal flour of  claim 1 , wherein the biomass comprises between 45% and 70% by dry weight triglyceride oil. 
     
     
         7 . The microalgal flour of  claim 1 , wherein 60%-75% of the triglyceride oil is an 18:1 lipid in a glycerolipid form. 
     
     
         8 . The microalgal flour of  claim 1 , wherein the triglyceride oil is:
 a. less than 2% 14:0;   b. 13-16% 16:0;   c. 1-4% 18:0;   d. 64-70% 18:1;   e. 10-16% 18:2;   f. 0.5-2.5% 18:3; and   g. less than 2% oil of a carbon chain length 20 or longer.   
     
     
         9 . The microalgal flour of  claim 1 , wherein the biomass is between 25%-40% carbohydrates by dry weight. 
     
     
         10 . The microalgal flour of  claim 9 , wherein the carbohydrate component of the biomass is between 25%-35% dietary fiber and 2%-8% free sugar including sucrose, by dry weight. 
     
     
         11 . The microalgal flour of  claim 1 , wherein the monosaccharide composition of the dietary fiber component of the biomass is:
 a. 0.1-4% arabinose;   b. 5-15% mannose;   c. 15-35% galactose; and   d. 50-70% glucose.   
     
     
         12 . The microalgal flour of  claim 1 , wherein the biomass has between 20-115 μg/g of total carotenoids, including 20-70 μg/g lutein. 
     
     
         13 . The microalgal flour of  claim 1 , wherein the chlorophyll content of the biomass is less than 2 ppm. 
     
     
         14 . The microalgal flour of  claim 1 , wherein the biomass has 1-8 mg/100 g total tocopherols, including 2-6 mg/100 g alpha tocopherol. 
     
     
         15 . The microalgal flour of  claim 1 , wherein the biomass has 0.05-0.30 mg/g total tocotrienols, including 0.10-0.25 mg/g alpha tocotrienol. 
     
     
         16 . The microalgal flour of  claim 1  in the form of a food ingredient composition, wherein the microalgal flour is combined with one or more additional edible ingredients that is a grain, fruit, vegetable, protein, herbs, spices, or one or more ingredients for preparation of a salad dressing, egg product, baked good, bread, pasta, sauce, soup, beverage, frozen dessert, butter or spread. 
     
     
         17 . The microalgal flour of  claim 1  that is lacking visible oil. 
     
     
         18 . The microalgal flour of  claim 1 , further comprising a flow agent. 
     
     
         19 . The microalgal flour of  claim 1 , further comprising an antioxidant. 
     
     
         20 . The microalgal flour of  claim 1 , wherein the biomass is derived from a single strain of microalgae. 
     
     
         21 . The microalgal flour of  claim 1 , wherein the biomass is derived from an algae that is a species of the genus  Chlorella.    
     
     
         22 . The microalgal flour of  claim 19 , wherein the algae is  Chlorella protothecoides.    
     
     
         23 . The microalgal flour of  claim 1 , wherein the biomass is derived from an algae that is a color mutant with reduced color pigmentation compared to the strain from which it was derived. 
     
     
         24 . The microalgal flour of  claim 1 , wherein the algal biomass is derived from algae cultured heterotrophically. 
     
     
         25 . The microalgal flour of  claim 1 , wherein the algal biomass is derived from algae cultured and processed under good manufacturing practice (GMP) conditions. 
     
     
         26 . A food ingredient composition comprising or formed by combining: (a) at least 0.5% w/w microalgal flour, wherein the microalgal flour is a homogenate containing predominantly or completely lysed microalgal cells in the form of a powder comprising at least 16% by weight triglyceride oil, and (b) at least one other edible ingredient, wherein the food ingredient composition can be converted into a reconstituted food product by addition of a liquid to the food ingredient composition. 
     
     
         27 . The food ingredient composition of  claim 26  that is a dry pasta. 
     
     
         28 . The food ingredient composition of  claim 26 , wherein the food ingredient composition can be converted into a reconstituted food product by the addition of liquid followed by baking. 
     
     
         29 . The food ingredient composition of  claim 26 , wherein the reconstituted food product is a liquid food product. 
     
     
         30 . The food ingredient composition of  claim 29 , wherein the food ingredient composition can be converted into the reconstituted food product by a process including subjecting the product of reconstitution to shear forces. 
     
     
         31 . The food ingredient composition of  claim 29 , wherein the average size of particles of microalgal biomass in the liquid food product is between 1 and 15 μm. 
     
     
         32 . The food ingredient composition of  claim 26 , wherein the reconstituted food product is an emulsion. 
     
     
         33 . The food ingredient composition of  claim 26 , wherein the reconstituted food product is a salad dressing, soup, sauce, beverage, butter or spread. 
     
     
         34 . The food ingredient composition of  claim 26 , wherein the reconstituted food product contains no oil or fat other than oil from the microalgal biomass. 
     
     
         35 . The food ingredient composition of  claim 26 , wherein the amount of microalgal flour in the reconstituted food product is 0.25-1 times the weight of oil and/or fat in a conventional food product of the same type as the reconstituted food product. 
     
     
         36 . The food ingredient composition of  claim 26 , wherein the average size of particles of microalgal biomass is less than 100 μm. 
     
     
         37 . The food ingredient composition of  claim 26 , wherein the average size of particles of microalgal biomass is 1-15 μm. 
     
     
         38 . The food ingredient composition of  claim 26 , having a moisture content of 10% or less or 5% or less by weight. 
     
     
         39 . The food ingredient composition of  claim 26 , wherein the microalgal biomass comprises between 45% and 65% by dry weight triglyceride oil. 
     
     
         40 . The food ingredient composition of  claim 26 , wherein 60%-75% of the triglyceride oil is an 18:1 lipid in a glycerolipid form. 
     
     
         41 . The food ingredient composition of  claim 26 , wherein the triglyceride oil is:
 a. less than 2% 14:0;   b. 13-16% 16:0;   c. 1-4% 18:0;   d. 64-70% 18:1;   e. 10-16% 18:2;   f. 0.5-2.5% 18:3; and   g. less than 2% oil of a carbon chain length 20 or longer.   
     
     
         42 . The food ingredient composition of  claim 26 , wherein the microalgal biomass is between 25% to 40% carbohydrates by dry weight. 
     
     
         43 . The food ingredient composition of  claim 26 , wherein the carbohydrate component of the microalgal biomass is between 25%-35% dietary fiber and 2% to 8% free sugar including sucrose, by dry weight. 
     
     
         44 . The food ingredient composition of  claim 26 , wherein the dietary fiber component of the microalgal biomass is:
 a. 0.1-4% arabinose;   b. 5-15% mannose;   c. 15-35% galactose; and   d. 50-70% glucose.   
     
     
         45 . The food ingredient composition of  claim 26 , wherein the microalgal biomass comprises between 20-115 μg/g of total carotenoids, including 20-70 μg/g lutein. 
     
     
         46 . The food ingredient composition of  claim 26 , wherein the microalgal biomass comprises less than 2 ppm chlorophyll. 
     
     
         47 . The food ingredient composition of  claim 26 , wherein the microalgal biomass comprises 1-8 mg/100 g total tocopherols, including 2-6 mg/100 g alpha tocopherol. 
     
     
         48 . The food ingredient composition of  claim 26 , wherein the microalgal biomass comprises 0.05-0.30 mg/g total tocotrienols, including 0.10-0.25 mg/g alpha tocotrienol. 
     
     
         49 . A method of making a microalgal flour comprising:
 a. providing microalgal cells containing at least 16% by dry weight triglyceride oil;   b. disrupting the cells and reducing the particle size to produced an aqueous homogenate;   c. drying the homogenate to produce microalgal flour comprising at least 16% by dry weight triglyceride oil.   
     
     
         50 . The method of  claim 49 , further comprising separating the microalgal cells from culture media before disrupting the cells. 
     
     
         51 . The method of  claim 49 , wherein the disruption is performed using a pressure disrupter, French press, or ball mill. 
     
     
         52 . The method of  claim 49 , wherein the drying is performed using a lyophilizer, drum dryer, flash dryer, spray dryer, or box dryer. 
     
     
         53 . The method of  claim 49 , wherein the microalgal cells contain between 50% and 65% by dry weight oil. 
     
     
         54 . The method of  claim 49 , further comprising adding a flow agent at any point during the process. 
     
     
         55 . The method of  claim 49 , wherein the average size of particles in the flour is less than 100 μm. 
     
     
         56 . The method of  claim 55 , wherein the average size of particles of flour are between 1 and 15 μm. 
     
     
         57 . The method of  claim 49 , wherein the flour has a moisture content of 10% or less or 5% or less by weight. 
     
     
         58 . The method of  claim 49 , wherein 50%-75% of the oil is an 18:1 lipid in a glycerolipid form. 
     
     
         59 . The method of  claim 49 , wherein the oil is:
 a. less than 2% 14:0;   b. 13-16% 16:0;   c. 1-4% 18:0;   d. 64-70% 18:1;   e. 10-16% 18:2;   f. 0.5-2.5% 18:3; and   g. less than 2% oil of a carbon chain length 20 or longer.   
     
     
         60 . The method of  claim 49 , wherein the cells are of a single strain of microalgae. 
     
     
         61 . The method of  claim 49 , wherein the cells are a species of the genus  Chlorella.    
     
     
         62 . The method of  claim 61 , wherein the cells are  Chlorella protothecoides.    
     
     
         63 . The method of  claim 49 , wherein the cells are of a color mutant strain with reduced color pigmentation compared to the strain from which it was derived. 
     
     
         64 . The method of  claim 49 , wherein the cells are from a heterotrophic culture. 
     
     
         65 . The method of  claim 49 , wherein the cells are disrupted and dried under good manufacturing practice (GMP) conditions. 
     
     
         66 . A method of making food product from microalgal flour, comprising:
 a. determining an amount of microalgal flour to include in the food product based an amount of oil, fat or eggs in a conventional form of the food product, wherein the microalgal flour is a homogenate of microalgal biomass containing predominantly or completely lysed cells in the form of a powder comprising at least 16% by dry weight triglyceride oil; and   b. combining the amount of microalgal flour with one or more edible ingredients and less than the amount of oil, fat or eggs present in the conventional form of the food product to form the food product from the microalgal flour.   
     
     
         67 . The method of  claim 66 , wherein the food product contains less than 25% oil or fat by weight, excluding microalgal oil contributed by the biomass. 
     
     
         68 . The method of  claim 66 , wherein the food product from microalgal flour contains less than 10% oil or fat by weight, excluding microalgal oil contributed by the biomass. 
     
     
         69 . The method of  claim 66 , wherein the food product from microalgal flour is free of oil or fat excluding microalgal oil contributed by the biomass. 
     
     
         70 . The method of  claim 66 , wherein the food product from microalgal flour is free of eggs. 
     
     
         71 . The method of  claim 66 , wherein the food product is free of oil other than microalgal oil contributed by the biomass.