Microbial DHA Oil Extraction Without Solvent-Based Ester Conversion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing high docosahexaenoic acid (DHA) oils involve chemical transformations that alter the natural composition, introduce contaminants, and require costly, environmentally harmful processes, making them unsuitable for applications requiring high DHA content and minimal processing.

Innovation Solution

A microbial oil rich in DHA, comprising at least 60% DHA, 80% triglycerides, and less than 25% saturated fatty acids, produced through natural extraction without ethyl ester conversion or solvent use, ensuring minimal contaminants and maintaining natural antioxidant protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If oils are concentrated by converting triglycerides to ethyl esters using solvents, then PUFA content is increased, but bioavailability decreases and contaminants are introduced

Engineering Contradiction:
ImprovePUFA contentVSAvoidbioavailability
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent extracts and concentrates PUFA from microalgal biomass through direct lipid extraction using supercritical carbon dioxide, obtaining a concentrated oil rich in triglycerides without converting them to ethyl esters. This maintains the natural triglyceride form for optimal bioavailability while achieving high PUFA concentration (60-80% of total fatty acids).

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the physical parameters of carbon dioxide to a supercritical state (high pressure and temperature) for extraction, then returns it to gaseous state for easy separation. This parameter change enables concentration of PUFA without chemical transformation, preserving the triglyceride structure and avoiding solvent residues.

Inventive Principle:
Principle #35Parameter changes

2Quantity of substance

If chemical transformation processes are used to concentrate oils, then PUFA content is increased, but harmful contaminants are introduced

Engineering Contradiction:
ImprovePUFA contentVSAvoidcontaminants
Core Design Contradiction:
Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent turns the typically harmful high-pressure and high-temperature conditions into a beneficial supercritical state of carbon dioxide that acts as a clean extraction medium. The supercritical CO2 selectively extracts lipids while leaving behind cellular debris and contaminants, then easily evaporates without residue, converting what could be harsh conditions into a gentle concentration process.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Quantity of substance

If multiple transformation processes are applied to concentrate oil, then DHA content is increased, but production cost increases

Engineering Contradiction:
ImproveDHA contentVSAvoidproduction cost
Core Design Contradiction:
Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent implements a continuous supercritical extraction process where carbon dioxide is continuously circulated through the microalgal biomass, extracting lipids in a single continuous operation. This eliminates the need for multiple batch processing steps, chemical treatments, and intermediate purification stages, significantly reducing production time and cost while achieving high DHA concentration.

Inventive Principle:
Principle #20Continuity of useful action

4Quantity of substance

If solvents are used for concentration, then PUFA content is increased, but environmental impact worsens

Engineering Contradiction:
ImprovePUFA contentVSAvoidenvironmental impact
Core Design Contradiction:
Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent replaces traditional chemical solvent systems with a physical field-based supercritical fluid extraction system. By utilizing the unique properties of supercritical carbon dioxide (a physical state rather than a chemical reaction), the process achieves concentration without introducing persistent chemical contaminants into the environment, and the CO2 can be recycled and reused.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a high DHA content oil with reduced contaminants, improved bioavailability, and enhanced stability, suitable for human and animal nutrition, particularly for infants, while minimizing environmental impact.

Implementation Method 1

Many strains of microorganisms are known to produce PUFAs, in particular docosahexaenoic acid (DHA)... These PUFAs are widely used in industry, in particular for human or animal food

Methodology Applied
Scientific EffectLipid metabolism:

Implementation Method 2

The oil can be extracted from the biomass of the microorganisms

Methodology Applied
Scientific EffectSupercritical fluid extraction: Supercritical Fluid Extraction

Data Source

PatentUS12359231B2Oil of microorganisms rich in docosahexaenoic acid
Publication Date: 2025.07.15 FERMENTALG

AI summary

The present invention relates to an oil of microorganisms rich in docosahexaenoic acid (DHA, C22:6n3), comprising more than 60% of DHA relative to the total mass of fat and to the use thereof for human or animal feed, in particular for feeding infants, children, or pregnant or lactating women.