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Industrial scale-up of microalgal cultures is often a protracted step prone to culture collapse and the occurrence of unwanted contaminants. To solve this problem, a two-stage scale-up process was developed – heterotrophically  Chlorella vulgaris  cells grown in fermenters (1 st  stage) were used to directly inoculate an outdoor industrial autotrophic microalgal production unit (2 nd  stage). A preliminary pilot-scale trial revealed that  C. vulgaris  cells grown heterotrophically adapted readily to outdoor autotrophic growth conditions (1-m 3  photobioreactors) without any measurable difference as compared to conventional autotrophic inocula. Biomass concentration of 174.5 g L −1 , the highest value ever reported for this microalga, was achieved in a 5-L fermenter during scale-up using the heterotrophic route. Inocula grown in 0.2- and 5-m 3  industrial fermenters with mean productivity of 27.54 ± 5.07 and 31.86 ± 2.87 g L −1  d −1 , respectively, were later used to seed several outdoor 100-m 3  tubular photobioreactors. Overall, all photobioreactor cultures seeded from the heterotrophic route reached standard protein and chlorophyll contents of 52.18 ± 1.30% of DW and 23.98 ± 1.57 mg g −1  DW, respectively. In addition to providing reproducible, high-quality inocula, this two-stage approach led to a 5-fold and 12-fold decrease in scale-up time and occupancy area used for industrial scale-up, respectively.

Heterotrophy as a tool to overcome the long and costly autotrophic scale-up process for large scale production of microalgae