The Expansion of the AlgaeHUB®

by Lgem

Phase 1.

AlgaeHUB 2.0

Welcome to the AlgaeHUB e-magazine! In this magazine, we aim to inform you about the exciting expansion of AlgaeHUB. We are thrilled to take you on a journey where we show how we realized our vision. Our main goal of the expansion is to support your needs with our upgraded AlgaeHUB® services.

Lgem

We believe that algae are the answer to some of the greatest global challenges. Algae are becoming a dominant source of sustainable solutions, while applications are virtually endless. However, lack of industrial scalability creates a critical barrier to their immense potential. Questions about cost, quality, skilled labour, risk and productivity pose significant threats for further investments. Our approach at the AlgaeHUB proves that algae production can be done successfully and sustainably on an industrial scale. The scalable Lgem systems and genuine de-risking services have been the missing link in our industry.

AlgaeHUB®

We present our reliable and easy-to-use systems to produce microalgae at our cutting-edge AlgaeHUB®. In our completely unique 8000 m² facility near Amsterdam Schiphol Airport, we offer our latest technologies. The Lgem assortment ranges from 5 litre to modular production units for industrial production facilities for inside, outside and greenhouse solutions. At the AlgaeHUB® we have our product portfolio available with a tema of scientists to develop and optimize your microalgae driven production process. Along the way we obtain insights in sizes of unit operations required for your facility. De-risking allows validation of your business case on a commercially relevant scale. Our R&D services offer ground-breaking possibilities, solutions, and process improvements.

The Expansion

The expansion of AlgaeHUB® has been a result of careful planning and execution. With great enthusiasm, we have worked towards creating an advanced facility that is at the forefront of algae research and production. This e-magazine provides you with a unique opportunity to learn more about the various steps and processes that have contributed to the realisation of our ambitious project. From identifying the needs of our target audience to optimising processes and ensuring quality, we will share the key milestones and achievements with you.

The Expansion of the AlgaeHUB® by Lgem

Phase 1. Ideation, Goals, and Concept Development

Phase 2. Design Phase

Phase 3. Execution

Phase 4: System Construction and On-site Building

Phase 5: Process Optimization and Quality Assurance

Phase 6: Quality Control and Quality Assurance

Phase 7. Launch Event, Future Outlook & Customer Support

Phase 8. Get in Contact

Phase 1.

Ideation, Goals, and Concept Development

Phase 1.

AlgaeHUB 2.0

Lgem’s AlgaeHUB is a groundbreaking facility dedicated to expanding the potential of microalgae. The idea of expanding the AlgaeHUB involves recognizing the growing demand for AlgaeHUB services and understanding the specific needs of our target audiences. Implementing a place for research, validation, optimization, derisking and seed train optimization are the primary goals for expanding the AlgaeHUB.

The expansion of our facility will allow us to meet the increasing demands of our customers and offer an enhanced experience. By accommodating these requirements, we can ensure seamless processes, paving the way for achieving our goals and developing a concept that fulfills the needs of our clients.

Expansion for the PBR Systems

An important part of the AlgeaHub expansion is the Entos-45 system. The new AlgaeHUB is able to provide a space for the Entos-45 with a volume of 45³ or 45.000 litres, resulting in the largest operational volume in the products offered by Lgem. The entire environment surrounding the Entos-45 needs to be fully controlled with artificial lighting for an optimal algae growth. The new AlgaeHUB is a 8000 m² facility near Amsterdam Schiphol Airport and it is able to house these massive photobioreactors PBR.

It currently houses lab, pilot and 18 production units, a collaborative environment for research, development, and consultancy. It is the perfect space for a team of skilled bioprocess engineers, biologists, electrical, and software engineers to offer tailor-made algae solutions and production facilities to meet all needs.

“We pride ourselves in our partnerships, and together we can go to the next level.”

Phase 2.

Design Phase

Phase 1.

How Experts Designed the AlgaeHUB 2.0

Design and Infrastructure is a vital stage in the expansion of the AlgaeHUB, as it involves evaluating the existing facilities, determining the necessary spaces and infrastructure, and designing the new facility to better serve our clients’ needs.

The evaluation of current facilities is conducted to understand their strengths, limitations, and potential areas of improvement. This assessment helps inform the necessary changes and expansions needed for the AlgaeHUB’s growth.

During the design phase, careful consideration is given to laboratory equipment, industrial-scale photobioreactors (PBRs), permits, and up and downstream processing rooms. Collaboration ensures the new AlgaeHUB is designed to optimize productivity, efficiency, and safety. Factors such as spatial layout, equipment placement, workflow optimization, and adherence to industrial standards standards are taken into account. These insights are also used during the facility setup of cliënts.

The new AlgeaHUB Is designed with the following in mind:

More than doubling culture volume from 30 m³to 85 m³
Integrated Upstream and downstream unit operations
Fully controlled indoor entos-45 photobioreactor with integrated LED mounting.
Full control, nutrient dosing, artificial intelligence automation, industry 4.0
Fully dedicated seed train for scaling upcultures for production or derisking activities.
Expansion in the number of research systems, for Lab and pilot scale research activities:
5X Lab-25, 1X Lab-275, 4X Pilot-925, Pilot-1700 and Pilot-3450, Entos-45.
HAACP in place in preparation for further certifications.
High care DSP room with Lgem DSP unit and flexible slots for validating your process at an industrial scale.
Fully automated nutrient station, including water and nutrient recycling at scale.

Old Floor Plan

New Floor Plan

Phase 3.

Excecution Phase

Phase 1.

A Collaboration with Partners and Shareholders

During the Technical planning of the expansion of the AlgaeHUB, there is a strong emphasis on acquiring advanced equipment and technologies necessary for conducting cutting-edge algae research, recognizing that servicing the external demand is of paramount importance to the project’s success. Collaborating with shareholders and other partners not only enriches the technical planning process but also underscores the significance of meeting the needs of external stakeholders.

Our partners and their expertise in system production, plays a vital role in this phase. Their state-of-the-art, highly automated production facility is responsible for manufacturing the Lgem PBRs (Photobioreactors) needed for the expanded AlgaeHUB. These PBRs undergo meticulous assembly, thorough checks, and rigorous testing by a highly skilled team, ensuring the highest quality standards.

Production Process

State-of-the-Art Equipment Enabling Groundbreaking Research

The execution phase also encompasses the design and integration of the various unit operations that make up the entire process: upstream, photobioreactors and harvesting (DSP). Each aspect, from the selection of specialized equipment to the layout of the facility, is carefully considered to optimize research capabilities. The AlgaeHUB’s expansion design incorporates the requirements of conducting advanced algae research, ensuring a seamless workflow and efficient utilization of resources.

The AlgaeHUB leverages the expertise and capabilities of partners to enable groundbreaking research and development with state-of-the-art equipment. Lgem manufactures industrial-quality products with minimal margin deviations and software integration, unlike others in the market. The products include a nutrient station, PBRs, and DSP. The technical planning phase ensures that the expanded facility supports the exploration of new possibilities and advancements in algae production and its applications.

Phase 4.

System Construction and On-site Building

Phase 1.

Optimal Growth Conditions

The construction phase of the AlgaeHUB expansion focused on the construction and installation of specialized indoor, outdoor and greenhouse algae cultivation systems required for production research from lab to industrial scale. The construction process commenced in December 2022, starting from the groundwork, including the installation of piping and concrete structures, to the assembly of the first systems and monitoring systems.

During this phase, meticulous attention is given to creating optimal growth conditions for a wide variety of algae. The greenhouse cultivation systems are designed to provide precise control and management over environmental factors such as light, temperature, nutrient availability, and pH levels. These systems incorporate advanced monitoring, control and management mechanisms to ensure the continuous process monitoring and adjustment of growth parameters, maximizing the productivity and health of the algae cultures.

Seamless Integration

The construction and installation teams work diligently to ensure the seamless integration of the specialized algae cultivation systems within the AlgaeHUB facility. Their expertise and attention to detail ensure that the systems are assembled, calibrated, and thoroughly tested to meet the highest quality standards.

The AlgaeHUB expansion paves the way for efficient and scalable algae production and reduced operational risks. The construction phase brings the infrastructure and equipment together, setting the stage for the subsequent stages of operation and research within the expanded facility.

Construction of AlgeaHUB and Systems

Phase 5.

Process Optimization and Quality Assurance

Phase 1.

A Comprehensive Evaluations of the Production Workflows

Phase 5 of the AlgaeHUB expansion focuses on process optimization and quality assurance. This phase is important for ensuring the efficiency and consistency of production workflows in the microalgae production process.

During this phase, comprehensive evaluations of the production workflows are conducted to identify areas for improvement. The goal is to streamline processes, eliminate bottlenecks, and maximize productivity. Through careful analysis and data-driven insights, adjustments and enhancements are made to optimize resource utilization, minimize waste, and enhance overall efficiency.

Quality assurance measures are of paramount importance in the AlgaeHUB expansion. Strict protocols and standards are implemented to guarantee consistent and reliable results. This includes rigorous quality control checks at various stages of the production process to ensure that the desired specifications and parameters are met.

The implementation of robust quality assurance measures

Continuous monitoring and analysis of key performance indicators enable proactive identification and mitigation of any deviations or potential issues, ensuring the highest levels of quality.

The implementation of robust quality assurance measures includes the use of advanced technologies, standard operating procedures and a highly skilled and trained workforce. Regular audits, software implementation, inspections, and certifications further validate the adherence to quality standards and regulatory requirements.

By focusing on process optimization and quality assurance, the AlgaeHUB expansion ensures the delivery of high-quality products and services to its customers. This phase lays the foundation for consistent and efficient production, further reinforcing the reputation of the Lgem as a trusted and reliable provider in the field of algae cultivation and research.

Phase 6.

Quality Control and Quality Assurance

Phase 1.

Testing and Experimenting

In Phase 6 of the AlgaeHUB expansion, rigorous testing and quality assurance processes are conducted to ensure the functionality and performance of the expanded facility.

Various tests and experiments are carried out by Lgem to validate the AlgaeHUB operations. These tests include, technical and functional prototype tests, water tests, software testing and light tests to assess the efficiency and effectiveness of the designed cultivation systems.

Through these experiments, we gather valuable data and insights regarding the growth and behavior of the algae. We evaluate the performance of the expansion of the algeahub accurately, ensuring that the systems meet the desired specifications and requirements.

Water test Pilot-3450

Light test Pilot-3450

Optimization of Operations

The analysis of test results plays a crucial role in this phase. Detailed examination and interpretation of the data allow us to evaluate the performance of the upgraded AlgaeHUB accurately. If necessary, adjustments to processes and parameters are made to optimize productivity, enhance quality, and ensure consistent results. This iterative approach allows us to fine-tune the operations and address any potential challenges or opportunities for improvement.

By conducting comprehensive testing and quality validation, the AlgaeHUB reaffirms its commitment to delivering reliable and high-quality products. The results of these tests not only validate the functionality of the facility but also provide valuable insights for ongoing research and development. This phase establishes a solid foundation for the continued success and innovation within the expanded AlgaeHUB.

Validation run with Nannochloropsis oculata in Pilot-3450

Phase 7.

Launch Event, Future Outlook & Customer Support

Phase 1.

The Official Launch

Phase 7 marks the culmination of the AlgaeHUB expansion, featuring the official launch event where we announce the expanded facility to customers and stakeholders. This milestone celebration highlights the growth and progress achieved, showcasing our commitment to innovation and excellence in algae research and production.

Looking ahead, the future of the AlgaeHUB is filled with exciting new possibilities and challenges in the field of algae, leveraging our state-of-the-art technology and expertise to create sustainable solutions for various industries and applications. We envision further milestones, breakthroughs, and advancements in algae production and its applications.

Through ongoing research, collaboration with partners, and continuous improvement of the Lgem systems, we strive to unlock the full potential of microalgae and create new value chains for our customers.

Customer support remains at the forefront of our commitment. We are dedicated to providing exceptional service to our valued customers. Our customer support team is readily available to address inquiries, offer guidance, and assist with any challenges that may arise.

Continuously Providing High-Quality

Commitment to Customers

We actively gather feedback from our customers, valuing their input to further enhance our service delivery and ensure their satisfaction.

By continuously improving our operations, refining our processes, and staying responsive to customer needs, we aim to exceed expectations and deliver the highest level of service. The expanded AlgaeHUB embodies our vision for the future, where innovation, sustainability, and customer-centricity are at the core of our endeavors.

As we embark on this exciting new phase, we extend our gratitude to all our customers, partners, and stakeholders for their support and collaboration. Together, we will continue to push the boundaries of algae cultivation, explore new frontiers, and make a positive impact in the world of sustainable biotechnology.

Get in Contact

Visit the AlgaeHUB

Phase 1.

Get in contact with us

We want to invite you to visit algaeHUB, the ultimate destination for all things algae and innovative, where you can explore, invent and produce to revolutionize the world of algae!