Eco Farm

Hundreds of aquatic organisms can bloom in nutrient‑rich water under warm sunlight, making it challenging to maintain a pure spirulina culture. Removing unwanted microscopic algae—commonly known as weed algae—is a complex task. Preventing these competitors from taking over is essential to producing high‑quality spirulina. Earthrise® scientists achieve this without toxic chemicals by using a specially designed pond system and carefully managing the pond’s ecological balance.

In a remote, sun‑drenched region of California—far from cities, highways, and airports—the air is exceptionally clean. Mineral‑rich Colorado River water, which supplies seven states across the U.S. Southwest, is delivered through canals to large settling ponds, then filtered before entering the cultivation ponds. The production system operates as a closed loop: water and nutrients are continuously recycled, with no discharge to the surrounding environment.

Our 37 spirulina ponds are lined with food‑grade materials to ensure purity and safety. Each pond covers 5,000 square meters—more than an acre in size and larger than a football field. Clean, fresh water and precisely balanced nutrients are added daily to nourish the algae, while 50‑foot paddlewheels in each pond provide continuous mixing to maintain optimal growing conditions.

Adding manure or other organic matter directly to the water can foul the shallow ponds, disrupt algae growth, and introduce unpleasant odors. For this reason, only clean and pure mineral nutrient sources are used. Premium‑quality minerals—including nitrogen, potassium, iron, and essential trace elements—provide optimal nourishment, supporting the consistent production of high‑quality spirulina.

Plant leaves absorb carbon from carbon dioxide (CO₂) in the air, but algae require carbon to be dissolved directly in the water. Because spirulina grows extremely rapidly, atmospheric CO₂ cannot enter the water fast enough to support optimal growth. To meet this demand, carbon must be added directly. The same high‑quality CO₂ used in carbonated beverages is carefully injected into the ponds to provide a clean, consistent carbon source.

During the growing season, from April through October, the ponds are harvested daily. Under peak summer sunlight, harvesting continues around the clock—24 hours a day—to keep pace with spirulina’s exceptionally rapid growth rate.

During its brief journey through our stainless‑steel harvesting and drying system, spirulina is never touched by human hands. An initial screen removes any pond debris, followed by finer screens that gently harvest the microscopic algae. The nutrient‑rich water is then recycled back to the ponds. A final filtration step concentrates the spirulina from a green, yogurt‑like consistency into a dense green dough. At this stage, the spirulina cells still contain approximately 80% water and must be dehydrated immediately to preserve quality.

Spirulina droplets are sprayed into the drying chamber, where the water is flash‑evaporated almost instantly. The resulting dry powder is exposed to gentle heat for only a few seconds as it falls to the bottom of the chamber, then vacuum‑conveyed into a collection hopper in the packaging room. This rapid, controlled process preserves heat‑sensitive nutrients, natural pigments, and enzymes—without the use of preservatives or stabilizers.

The final spirulina powder retains a high concentration of heat‑sensitive phycocyanin, demonstrating the effectiveness and gentleness of the drying process. When properly packaged in specialized oxygen‑barrier containers, freshly dried spirulina can be stored for four years or longer while retaining nearly its full beta‑carotene potency.

Fresh spirulina powder is cold‑compressed directly into tablets, without the use of heat or granulation. Using modern packaging technology, the tablets are automatically filled into protective aluminum bags that provide an effective barrier against oxygen, light, and moisture. The finished packages are then sealed and prepared for shipment to customers.