Super Critical

Pioneer  Enterpirse  provides the option of contract/custom manufacturing for companies worldwide. This will allow you to outsource several steps in the manufacturing process and execute those steps in India at very affordable prices. The facilities available are of world class and provide a facility for supercritical extraction for botanical and natural extracts production at very competitive price. Pioneer Enterprise and its associated companies specialize in Super Critical Fluid Extraction (SCFE), the most advanced extraction technology. Pioneer also offers extracts that enable our customers to meet the increasingly stringent statutory regulations of FDA and other such health organizations.

Products and services of Pioneer are specially dedicated to dietary suppliments flavours, fragrances, nutraceuticals, pharmaceutical/food ingredients, cosmetic ingredients, concentrates of natural botanicals for spice and condiments, fruit juice concentrates etc. These extracts are obtained through supercritical extraction of solid/liquid material, and supercritical fractionation.

We have expertise in SCFE CO2 technology for more than a decade and we have experience in every aspect of this technology and we can provide consultancy, contract manufacturing and turnkey project as per your requirements.

 

Super Critical Fluid Extraction Facility

SUPERCRITICAL FLUID EXTRACTION USING CARBON DIOXIDE

 

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The extraction Process

  • The residue consists all other substances that are present in the feed. The oil soluble substances are a range of chemicals with different molecular weights. They exhibit a solubility pattern
  • inversely proportional to their molecular weights at any given temperature and pressure. The presence of different organic substituted groups also affects the solubility.
  • Lower molecular weight components are extracted faster and have higher solubility in CO2, while higher molecular weight components have a lower solubility and consequently lower extraction rates.
  • Once the extract is obtained, it is clarified, and water is separated out and the material is filled in containers. This extract is called the total extract.

Supercritical fractionationSometimes there is a need to separate the low boiling essential oils or other active ingredients from the high boiling components of the combined total extract. This can be done using our liquid supercritical fractionation column. This is a continuous operation w.r.t. both the extract and CO2. The bottom end of the fractionator is a mixture of unextracted material. The top section carries the extracted low boiling components along with CO2.Comparison with other extraction techniques
Let us elaborate some more points about the superiority of the SCF extraction by citing an example of ginger.Essential oils (EO) contain two basic ingredients:Monoterpenes– non-oxygenated hydrocarbons, which are of little importance as perfumery materials.Sesquiterpenes– Oxygenated hydrocarbons which are of high importance as perfumery materials.The EO’s obtained from steam distillation contain only monoterpenes and other hydrolyzed products. Hence they are relatively cheap as well as inferior in quality. The Sesquiterpenes cannot be steam distilled. These can however be easily extracted using SCF extraction and hence the quality of the extract is far superior.Salient features of SCF extraction:The extracts are free of the following undesirable components:

  • Solvent residues
  • Decomposition or hydrolysis products
  • Heavy metals
  • Inorganic substances
  • Polar substances

The extracts are clear, transparent, and contain almost every non-polar ingredient present in the original raw material. The moisture content is also reduced by physical separation.Plant and Machinery:We manufacture and supply Plant & Machinery for establishing SCFE facilities for our customers These include :Pilot plants are included for each one of them on size basis. These are based on experience and design of both the partner and the company. The Indian company has fabricated all the equipment itself, erected and commissioned this Indian facility.solid raw material based: Batchwise operation for solid material of extraction.Apart from following standard capacities,other capacities are also possible as per customer need.

5 lit. * 2 extractors (10 lit.plant)

10 lit. * 2 extractors (20 lit.plant)

100 lit. * 3 extractors (300 lit.plant)

165 lit. * 3 extractors (500 lit.plant)

These are two or three extractor based systems in a common circuit for the extraction fluid (CO2) with arrangement to

  • Auto switch over of extractors.’
  • Pressure & temperature control
  • PLC for continuous operation.
  • Data loggers for recording etc.

Design takes care of minimum manpower requirement. The utilities involve chilled water, brine plant, cooling tower & hot water units, instrument air, CO2 liquid storage, fuel storage and handling. CO2 recovery and recycle system is optional.Salient Features:

  • Quick opening single bolt extractor lid enables lowest labour and time dependence.
  • Lowest extractant cost due to  low loss.
  • Lowest manpower requirement.
  • Reliable components assure lowest shut down.International design & fabrications codes are followed during manufacturing the plant and machinery.
  • Material of construction (stainless steel) makes it long lasting & compatible for applications.
  • Bare minimum imported components for improving reliability, spares availability is fast.
  • Highly polished surfaces to enable quick product change over.
  • International safety standards are used to make the installation safe.
  • Two pressure separation system can be provided as optional item.
  • Quick material loading / unloading by either use of basket or vacuum sucking.
  • Processing / extraction capacity varies as per the material processed and extract desired i.e selective or total etc.
  • Maximum pressure 350 bar as standard supply.

SCFE raw material based:Plant capacities offered are 2lit., 5lit,. 30lit., 50lit., extractor based. The plant receives the feed and the extractant fluid continuously & is operated continuously to fractionate the feed into two fractions. Maximum operations pressure 300 bar as standard supply.Salient Features:

  • Low dismantling and cleaning time during product change over
  • Continuous steady state operation is possible.
  • Lowest manpower requirements.
  • Reliable components assure lowest shut down.
  • Material of construction (stainless steel), makes it long lasting & compatible for food  pharmaceutical applications.
  • Bare minimum imported components for reliability, spares availability is fast.
  • Highly polished surfaces to enable quick product change over.
  • International design & fabrications codes are followed in manufacturing the plant and machinery.
  • International safety standards are used to make the installation safe.
  • Processing / extraction capacity varies as per the material processed and extract desired i.e selective or total etc.

DISINFECTION PLANT:The insects, micro organic life etc. are the major cause of spoiling of botanical material during storage of the farm produce even after drying.The various convectional practices adopted for preservation  which use noxious chemicals, contaminate the preserved material due to its presence . The treatment of these items using CO2 under pressure, avoids all health hazards at the same time it kills the above life in place. The treatment is done in “quick opening lid type” pressure vessel provided with trolleys, gas extraction and purging system. The technology and engineering is developed in Germany by our patners. The plant is fully PLC operated & depends on human interface for loading and unloading.Shelf life of treated material  is improved and spoiling in storage is brought down to negligible..These plants are available in various batch treatment capacities as follows

2000lit. * 2 processors.

4000lit. * 2 processors.

6000lit. * 2 processors.

This operates batch wise.The remaining part of the plant to handle CO2 is common.Salient Features:

  • Quick opening  covers of processing vessel   facilitate almost negligible time loss compared to total time cycle & requires only one person.
  • Lowest operating cost due to recycle of CO2 leading to lower CO2 consumption.
  • Lowest initial cost, as material of construction is carbon steel
  • Lowest manpower requirement.
  • Reliable components assure lowest shut down.International design & fabrications codes are followed during manufacturing the plant and machinery
  • International safety standards are used to make the installation safe.

No

Solvent extraction

SCF extraction

1Solvent presence is unavoidable. The residual ppm level of the solvent depends on the type of solvent used.Is totally free of solvents and hence very pure2Heavy metal content is also unavoidable and depends on the solvent, the recycle method for the solvent, the source of the raw material, and the material of construction of the contact parts of the machinery.Totally free of heavy metals since they are not extractable even if they are present in the raw material. No heavy metals are present in CO2 and the equipment3Inorganic salt content cannot be avoided, using the same concept as aboveTotally free of inorganic salts using the same explanation as above4Polar substances get dissolved along with the lipophilic substances from the raw material due to poor selectivity of the solvent. During solvent removal operation, these polar substances form polymers, which lead to dark color of extract and poor flow characteristics. All this renders the extract to look different from the basic components in the raw material and hence it is more of a “pseudo” natural extract.No such possibility since there is very high selectivity of CO2 and no chance of polar substances forming polymers. In addition the operating temperature is only 40-50 degree Celsius.5Both polar as well as non polar colors are extractedOnly non polar colors get extracted6Solvent removal requires extra unit operations and hence the cost and recovery of useful material is lowerNo extra unit operations needed and yield of useful material is very high