PharmaHemp, one of the world's leading companies in the field of research, development, processing, and laboratory testing of raw materials and industrial hemp products has taken a major step forward by acquiring a highly efficient CO2 extraction system that can be used to obtain plant extracts for the food, cosmetic, and pharmaceutical industries. High-quality materials, complete customer service, technical support, and proximity are just some of the reasons why the Slovenian company SK Škrlj from the Vipava Valley prevailed over its global competitors from Asia, America, and Europe.
From Pannonian Plain to Slovenian product
On the vast fields of the Pannonian Plain, September is the time of the harvest. The Slovenian company PharmaHemp has leased 400 hectares of land there and uses it to grow registered EU hemp varieties. After drying, the separation of stems, seeds, and leaves, and the grinding of individual parts of the plant, the harvested material was until recently sent on a long journey to Germany, to a factory equipped with high-capacity supercritical extraction systems, where the next step of the process took place.
Creating a new system - from idea to first launch
Purchasing their own extraction system was an important step, as was choosing the right manufacturer. Their new system was designed for the global market, so in addition to superior product quality, what ultimately tipped the scales in favor of SK Škrlj was their proximity, technical support, and personal approach to projects, as they always try and take into account customer demands and expectations. After careful review of the user requirements and the submitted specifications, engineers created an accurate three-dimensional model, which provided detailed insight into the product and the suitability of the proposed solution. When the system was finished in Batuje, they first conducted the so-called "Factory Acceptance Test", which consists of a test run and is performed in order to check system operation in accordance with the set parameters. Once the FAT was successfully completed, the system was transported to a new location and retested. The advantage of having the manufacturer close by is most obvious in the next phase of the purchase process, which includes system start-up and staff training. This is a great opportunity for additional explanations and to dispel any remaining doubts the new owner and future system operator may have regarding system management before taking over. According to Boštjan Jančar, Ph.D., CTO of PharmaHemp and a pioneer of industrial hemp product processing and production in Slovenia:
"From here on, it is on us to decide how we want to continue experimenting based on our prior knowledge."
Pump without servicing
The decision to buy such a large system was driven by several factors. Apart from its other high-quality and above-standard components, this extraction system also comes equipped with a timeless German membrane pump, which does not require servicing. Compared to other systems, this one has a very high CO2 flow rate, very high pressure (up to 500 bar), and is designed in accordance with Good Manufacturing Practice requirements. This means, among other things, that it records all process parameters and that the entire process is traceable, which is mandatory and extremely important in the pharmaceutical industry.
| GMP - Good Manufacturing Practice regulations ensure that the manufactured products are subject to strict quality control and standards in each stage of the production process (from raw material acceptance to final product packaging). |
Jančar also emphasizes the technical characteristics that strongly influenced their decision:
»With CO2 extraction, there are no residual solvents.«
There are many different extraction systems. In most cases, the extraction process is performed using organic solvents, most often ethanol, but a certain amount of the solvent always remains either in the biomass to be extracted or in the final product.
»The solvent used with our new system is carbon dioxide. When the pressure rises, only a minimal amount of CO2 is released into the environment, while most of it returns into the process, i.e., is recycled.«
A computer-controlled system that does not allow for human error
One of the main advantages of supercritical extraction is its efficiency, as it takes place under high pressures, but this also poses high safety risks. Compared to low-cost products available on the global market, the Škrlj system detects potential hazards and is fully automated which prevents errors due to human factors. The system is equipped with a Human Machine Interface (HMI) which enables recipe programming and monitors the entire extraction process - from raw material input to final extract. In case of deviations at any stage of the process, the system reports an error and alerts the operator. Due to the weight of the carbon dioxide, the system is equipped with built-in sensors, fuses at the bottom, which immediately issue a warning if there is a leak. In case of any problems, diagnostics can also be run remotely, as the system can be connected to a wireless network.
Changes in the quality of the final product
The purity of the final product is one of the main reasons why a company decides to opt for supercritical CO2 extraction. According to Jančar, the final product is created under the same conditions as before and the efficiency of the process also remains unchanged. The system is designed to operate 24 hours a day, seven days a week.