Mars has collaborated with researchers at King Abdullah University of Science and Technology (KAUST) in Saudi Arabia to convert chocolate factory waste into C-phycocyanin, a natural blue pigment used across food, cosmetics and pharmaceutical applications.
The research, published in Trends in Biotechnology, demonstrates how an ancient strain of red algae called Galdieria yellowstonesis can consume sugars from chocolate processing waste to produce the valuable pigment. The global market for C-phycocyanin is estimated to exceed 275 million US dollars by 2030.
Mars provided chocolate samples from its facility in King Abdullah Economic City for the research, which focused on utilizing waste generated when production lines start and stop. The company’s involvement showcases how major food manufacturers can support research into circular economy solutions for industrial waste streams.
“At Mars, we are committed to fostering innovation and sustainability through meaningful partnerships with leading academic institutions like KAUST,” said Obai Rahim, Mars Corporate Affairs Director for the Middle East and Africa. “This project reflects our dedication to advancing science and developing sustainable solutions, especially those that leverage local resources and expertise.”
Algae-based production offers cost advantages
The KAUST method using Galdieria offers significant advantages over conventional phycocyanin production, which relies on cyanobacteria. The red algae thrive in hot and highly acidic environments, which naturally reduces contamination from other microbes and can lower production costs while increasing yields.
Kyle Lauresen, KAUST associate professor and lead author of the study, said the research is uncovering new pathways for sustainable waste valorization. “Chocolate production, for example, generates waste when process lines start and stop,” Lauresen said. “We realized this waste could be a useful food for Galdieria.”
The research revealed an unexpected finding: high levels of carbon dioxide actively promote Galdieria growth. Typically, carbon dioxide is produced as waste when microbes metabolize sugar, but in this system, elevated CO2 concentrations enhance algae cultivation.
Phycocyanin from Galdieria was recently deemed food-safe by the U.S. Food and Drug Administration for use in beverages and other food applications. The blue pigment offers a natural alternative to artificial dyes in food manufacturing.
Circular economy applications for food producers
The process demonstrates potential for circular economy models in food manufacturing, where factory waste streams become feedstock for producing valuable ingredients. This approach addresses multiple sustainability challenges facing food producers, including production costs, waste management and climate change mitigation.
Rahim noted that the exploration of blue phycocyanin production from Galdieria grown on food waste aligns with Mars’ vision for sustainability and ongoing efforts to reduce food waste and promote circular economic practices. The company welcomed the KAUST research team to its King Abdullah Economic City facility as part of the collaboration.
For their experiments, Lauresen and his team collected waste directly from the chocolate factory in Saudi Arabia to test the algae cultivation process under real-world conditions.
The researchers plan to develop their process further by assessing scalability and technical capacity of Galdieria production on locally available waste streams. This work aims to help businesses in Saudi Arabia transition toward a circular carbon economy by demonstrating viable pathways for waste valorization.
