For optimizing the process of protein extraction through microalga Pseudochlorella pringsheimii, microwave-assisted extraction (MAE) was selected. After model validation and verification, the optimized values obtained for biomass concentration, microwave power and microwave time was 3.15 %, 200 W and 116 s, respectively. The extracted microalgae protein concentrates (MPC) were utilized for developing fortified high-protein buns. Comparative analysis of buns formulated by incorporating microalgae protein concentrate (MPC) and decolorized microalgae biomass (DMB) was carried out for nutritional, textural, and colour characteristics. The results revealed that fortification of buns with MPC significantly increased the protein content as compared to DMB fortified and control buns. The current work opens a new door for food industrialists to formulate products in such a way that can potentially enhance the nutritive properties (especially protein content) without adversely affecting its other desired characteristics. © 2025 Elsevier B.V., All rights reserved.