How We Work
From Ocean to Specification
A vertically integrated process — from strain selection and open-water cultivation through to GMP-compliant extraction, fractionation, and quality release.
Overview
Vertical Integration
Phycogel controls every stage of the supply chain. We select and maintain our own algal strains, operate licensed cultivation sites, and run our own extraction and processing facility. This means full traceability, consistent raw material quality, and the ability to respond rapidly to specification changes.
6
cultivation sites
across two coastal regions
400+
tonnes/year
dried biomass capacity
ISO 9001
certified
quality management system
GMP
compliant
extraction facility
Six Stages
The Full Process
Controlled genetic stock for consistent downstream yield
Strain Selection & Nursery
We maintain a library of authenticated red macroalgal strains — primarily Gracilaria, Kappaphycus, and Gelidium — selected for high polysaccharide yield, disease resistance, and growth rate. Seedling propagation is carried out in our land-based nursery under controlled salinity, temperature, and photoperiod conditions before transfer to open-water sites.
- Authenticated strain library with voucher specimens
- Land-based nursery propagation
- Seedling health screening before deployment
- Continuous strain improvement programme
Licensed coastal sites with monitored growth conditions
Open-Water Cultivation
Seaweed is cultivated on longline and net systems at licensed coastal sites. Water quality parameters — temperature, salinity, turbidity, and nutrient levels — are monitored continuously via in-situ sensors and satellite data. Harvest cycles are timed to peak biomass accumulation and optimal polysaccharide content.
- Longline and net cultivation systems
- Continuous water quality monitoring
- Satellite-assisted site management
- Harvest timing optimised for polysaccharide content
Rapid post-harvest handling to preserve bioactive integrity
Harvest & Primary Processing
Harvested biomass is transported to shore within four hours of cutting. It is washed, sorted for epiphyte load and morphological quality, then either sun-dried or oven-dried to target moisture specifications. Dried biomass is baled, sampled for QC, and either dispatched as raw material or transferred to the extraction facility.
- Shore-to-facility transfer within 4 hours
- Epiphyte and contaminant sorting
- Sun-dried and oven-dried options
- In-process moisture and ash testing
Aqueous and alkaline extraction under controlled conditions
Extraction & Fractionation
Dried biomass enters our GMP-compliant extraction facility where it undergoes hot aqueous or alkaline extraction depending on the target polysaccharide. Crude extracts are filtered, concentrated, and fractionated by molecular weight using membrane ultrafiltration. Intermediate products are tested for viscosity, gel strength, and bioactive concentration before proceeding.
- Hot aqueous and alkaline extraction
- Membrane ultrafiltration fractionation
- In-process viscosity and gel strength testing
- GMP-compliant facility with full batch records
Ion-exchange, bleaching, and spray or freeze drying to specification
Purification & Drying
Fractionated extracts are purified by ion-exchange chromatography or activated carbon treatment to remove colour, odour, and ionic impurities. Final drying is by spray drying or lyophilisation depending on the product grade and application. Dried product is milled to target particle size and blended for batch homogeneity.
- Ion-exchange and activated carbon purification
- Spray drying and lyophilisation
- Particle size milling and classification
- Batch blending for homogeneity
Full CoA with every batch — no release without passing specification
Quality Control & Release
Every batch is tested against a full specification panel before release. Testing includes purity by HPLC or gravimetric analysis, moisture, ash, heavy metals, microbial limits, and application-specific parameters such as gel strength, viscosity, or sulphate content. A Certificate of Analysis is issued with every shipment.
- HPLC and gravimetric purity analysis
- Heavy metals and microbial limit testing
- Gel strength and viscosity profiling
- Certificate of Analysis with every batch
GMP-compliant extraction from biomass to certified extract
Technology
Precision at Every Stage
Our facility combines established food-grade processing technology with analytical instrumentation typically found in pharmaceutical manufacturing. This allows us to serve both commodity food ingredient markets and high-specification pharmaceutical and cosmetic applications from the same production platform.
Membrane Ultrafiltration
Molecular weight fractionation from 1 kDa to 300 kDa cut-off, enabling precise polysaccharide fraction isolation.
Spray & Freeze Drying
Both drying modalities available on-site, allowing product form to be matched to application requirements.
In-line HPLC
Real-time purity monitoring during extraction and fractionation, reducing batch failure rates.
IoT Cultivation Monitoring
Sensor networks at all cultivation sites feed a central dashboard for real-time water quality and biomass growth tracking.
Discuss Your Processing Requirements
Whether you need a standard product or a custom extraction to your specification, our technical team can advise on feasibility, lead times, and minimum order quantities.