Development and Validation of an Automated Stirred-Tank Photobioreactor for Astaxanthin Production from Haematococcus pluvialis

The aim of this study was to design and validate an automated 5 L prototype Stirred-Tank Photobioreactor (ST-PBR) dedicated to the two-stage cultivation of the microalga Haematococcus pluvialis. The classic limitations of stirred-tank reactors (such as high shear stress and suboptimal light penetration) were overcome through precise phase-controlled illumination (60 and 300 μmol m−2 s−1) and the implementation of an advanced embedded control system integrated with Keysight VEE Pro 9.33 software. The design features an innovative mixing system utilizing a dual marine impeller driven by a brushless motor—operating at a mathematically defined tip speed of 0.48 m/s to preserve cellular integrity—alongside a precise gas dosing strategy (pH-stat) employing medical-grade components. Process verification demonstrated highly stable operation, maintaining a dry biomass concentration of 1.315 g/L with no recorded sedimentation, while achieving a highly competitive astaxanthin biosynthesis yield of 4.12% dry weight (DW). Furthermore, enzymatic extraction facilitated the recovery of a product with high biological activity, as confirmed by an increase in equine adipocyte viability up to 128.1 ± 3.1% in in vitro MTS assays, highlighting its potential for veterinary nutraceutical applications. The developed solution represents a scalable, cost-effective, and viable alternative to advanced tubular photobioreactors.