Microalgae are emerging as a promising feedstock for bioplastics, with Chlorella vulgaris yielding significant amounts of starch. This polysaccharide is convertible into thermoplastic starch (TPS), a biodegradable plastic of industrial relevance. In this study, we developed a pilot-scale protocol for extracting and purifying starch from starch-enriched Chlorella vulgaris biomass. From 430.3 ± 0.5 g (dry weight - DW) of microalgae biomass containing 42.2 ± 3.4 % of starch, we successfully extracted 205.8 ± 1.2 g DW of purified starch extract containing 86.9 ± 3.0 % of starch, resulting in a final recovery yield of 98.5%. We have characterized this extracted starch and processed it into TPS using twin-screw extrusion and injection molding. Microalgal starch showed similar properties to those of native plant starch, but with smaller granules. We compared the mechanical properties of microalgal TPS with two controls, namely a commercial TPS and a TPS prepared from commercial potato starch granules. TPS prepared from microalgal starch showed a softer and more ductile behavior compared to the reference materials. This study demonstrates the feasibility of recovering high-purity microalgal starch on a pilot scale with high yields, and highlights the potential of microalgal starch for the production of TPS using industrially relevant processes.