Algae thermoplastic composition and process of making

A method of forming a final product comprising an algae-based thermoplastic composition, the method comprising:

• (a) grinding an algae biomass into an algae powder having a particle size d99 of up to 200 microns;
• (b) drying the algae powder to form a relatively dried algae biomass powder having a moisture content of less than 15% by weight;
• (c) premixing and preheating a thermoplastic resin to a desired temperature and viscosity to form a molten thermoplastic;
• (d) mixing the algae powder with the molten thermoplastic forming a thermoplastic-algae blend;
• (e) optionally adding additives, plasticizers, compatibilizers and/or foaming agents;
• (f) dispersing the thermoplastic-algae blend;
• and
• (g) forming a predetermined final product using the algae-thermoplastic blend;
• wherein the thermoplastic composition defines an end-of-life emissions reduction of greenhouse gases (GHG) between 5% to 80% as compared to a composition of the resin from (b) absent the algae biomass.