A Multifunctional Saccharide “Trehalose”

World’s First Mass Production Through Enzyme Innovation

Trehalose (α-D-glucopyranosyl α-D-glucopyranoside) is a naturally occurring disaccharide prized for its ability to retain moisture and protect cellular structures. While long recognized for its unique properties, high production costs once made it impractical for widespread use—limiting its applications to niche pharmaceuticals and cosmetics.

In 1994, Nagase Viita became the first company in the world to mass-produce trehalose cost-effectively using proprietary microbial and enzyme technology. This achievement revolutionized access to trehalose, reduced its cost by more than 99%, and opened the door to new applications across food, personal care, pharmaceuticals, and agriculture.

The Impact of Mass Production

• Technological Breakthrough

  Pioneered large-scale production from starch using advanced microbial and enzyme technology.

• Dramatic Cost Reduction

  Lowered the market price to just 1% of its original cost, making trehalose broadly accessible.

• Expanded Applications

  Enabled use beyond niche markets to mainstream industries including food, personal care, pharmaceuticals, agriculture, and biotechnology.

1. What Is Trehalose?

Trehalose is found in everyday foods such as mushrooms, yeast, legumes, and seaweed. In nature, it plays a vital role in protecting organisms under stress, such as extreme heat or dehydration. A well-known example is Selaginella lepidophylla, the “resurrection plant,” which can survive near-complete dryness. Trehalose helps preserve its cellular structure, allowing the plant to revive when water returns.

Key Benefits of Trehalose

• Basic properties

  Mild Sweetness： Only 38% as sweet as table sugar (sucrose), making it ideal for delicate flavor profiles.

  High Stability： Resilient under heat and acidic conditions, outperforming many other sugars.

• Functionality for food

  Enhances food texture, extends shelf life, retains moisture, and suppresses starch retrogradation.

• Globally certified safety as food ingredient

  Approved by the Codex Alimentarius Commission and regulatory agencies worldwide

2. From Starch Syrup to Scientific Discovery

Redefining Saccharide Science

Nagase Viita traces its roots back to 1883 as a starch syrup producer. Over generations, the company built deep expertise in carbohydrate research, developing enzymatic methods to transform starch into valuable saccharides like glucose and maltose.

By the 1980s, nearly all commercially viable saccharides and sweeteners had already been industrialized, and the idea of creating entirely new sugars from starch was widely regarded as impossible. Yet, guided by the philosophy “Create what has never been done by challenging what others will not,” Nagase Viita researchers set out to break this barrier—ushering in one of the most important advances in carbohydrate biotransformation.

3. Discovery of Novel Enzymes from Soil Microbes

How Soil Screening Sparked a Breakthrough

To uncover enzymes capable of converting starch into trehalose, researchers collected and screened over 2,000 soil samples from across Japan. The breakthrough came from Okayama Prefecture—Nagase Viita’s own backyard—when a young scientist, Dr. Kazuhiko Maruta identified a strain of Arthrobacter that catalyzed a previously unknown conversion of starch to trehalose.

Despite skepticism in the academic community, Dr. Maruta proved trehalose could be synthesized from starch via a novel enzymatic pathway. His persistence, combined with a culture of encouragement at Nagase Viita, transformed scientific doubt into groundbreaking innovation.

As Dr. Maruta recalls, a supervisor’s encouragement— “Let’s keep pushing this research a little further”—became the spark that transformed persistence into breakthrough discovery.

4. Two Enzymes Behind the Breakthrough

Dual-Enzyme Process Delivering Cost-Effective Trehalose Production

Further research revealed that efficient trehalose synthesis required the combined action of two novel enzymes:

Working in sequence, these enzymes delivered an unprecedented 80% conversion efficiency—establishing the foundation for cost-effective industrial production.

Reflecting on this milestone, Dr. Maruta remembers his supervisor’s words: “You’re creating something truly remarkable here.” Those words underscored the significance of the discovery and inspired the team to press forward with confidence.

5. Achieving Mass Production in Just Two Years

A Company-Wide Effort

Once the pathway was confirmed, Nagase Viita mobilized a company-wide effort. Researchers, engineers, and technicians worked across disciplines to design new equipment, optimize processes, and secure patents. Remarkably, within just two years, trehalose entered mass production.

This milestone enabled trehalose to move from niche pharmaceutical use to everyday applications. In Japan, it was quickly adopted in confectionery, baked goods, and processed foods.

To meet rising global demand, Nagase Viita built a dedicated trehalose production facility in 2009 and expanded capacity further in 2016.

6. Expanding Applications to Food and Beyond

Trehalose’s Growing Role in Industry and Science

Thirty years since its commercialization, trehalose continues to prove it remarkable versatility, with research presented at the annual Trehalose Symposium underscoring its expanding role across global industries:

Nagase Viita remains committed to advancing trehalose research, improving product quality, and contributing to environmental sustainability and global well-being.

The Legacy of Innovation

The story of trehalose is more than a scientific milestone—it reflects Nagase Viita’s enduring spirit of curiosity and bold innovation. From soil samples collected in Okayama to global industrial production, the journey demonstrates how persistence, interdisciplinary collaboration, and scientific vision can transform an idea once deemed “impossible” into a solution that improves lives and industries around the world.

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Source: Nagase Viita, website A Multifunctional Saccharide “Trehalose”, https://group.nagase.com/viita/en/rd/story/01/

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