Algal Industry 5.0 for sustainable aquafeeds: integrating digital technologies and bioprocessing

Microalgae are recognized as a strategic and sustainable alternative to aquafeed ingredients due to their widespread availability and rich nutritional profile. However, the large-scale production of microalgae within the framework of Algal Industry 4.0, characterized by data-driven and automation-oriented algal biomanufacturing, continues to face significant challenges, including high energy consumption, process variability, contamination risks, low biomass productivity, and insufficient integration of intelligent management systems. These limitations can be addressed by introducing Algal Industry 5.0, which focuses on human-centric design, resilience production, and sustainability. Following a PRISMA-based protocol with bibliometric analysis of 210 studies (2020–2025) retrieved from Scopus, ScienceDirect, and Web of Science, this review critically evaluates recent advances in microalgae-based aquafeeds across open, closed, and hybrid cultivation configurations. A five-layer Algal Industry 5.0 model is established, integrating physical cultivation, digital, intelligent, and human-centric decision-making layers. Seven key enabling technologies were evaluated to support digital transformation, human-in-the-loop collaborative decision-support systems, digital twin models for real-time simulation, and AI-driven prediction and control of culture parameters in Algal Industry 5.0. These are complemented by cyber-physical cultivation systems, smart photobioreactor designs, and anomaly detection frameworks for adaptive process control. Blockchain-based traceability solutions and circular bioeconomy models further extend Algal Industry 5.0 across the value chain. Advanced bioprocess engineering, encompassing high-throughput strain screening, genetic and metabolic engineering, nanotechnology, bioinformatics, and advanced photobioreactor materials, is then examined as a critical enabler of resilient production and reliable supply chains that advance food security. By integrating technological, biological, and operational perspectives, this review systematically examines the operational, workforce, data-integration, and practical challenges of implementing Algal Industry 5.0 aligned with the United Nations Sustainable Development Goals on zero hunger (SDG 2), industry and innovation (SDG 9), and climate action (SDG 13).