Contract Services

In addition to standard botanical extract production services, Greenvit offers highly standardized specialist contract services in the field of spray drying and vacuum drying in two dynamically operating production facilities in Łomża and Zambrów.

For contract production, we offer:

  • efficient spray dryer
  • innovative vacuum-belt dryer
  • extraction services
  • R&D research
  • other specialist services

Applicable contract manufacturing standards

In communication with entities cooperating in the field of contract production, we emphasize that our role is not only to provide complementary products, but to support our clients at all stages of cooperation.

As contract manufacturers, we support brands in the areas of:

  • providing the best materials and ingredients,
  • process optimization by implementing the latest production and delivery technologies
  • standardization and compliance with regulatory requirements.

Before starting cooperation:

  • we set the scope of expectations and the rules for processing orders between the client and Greenvit, the contract manufacturer
  • we recommend a physical audit of the production plant
  • we emphasize the existence and recommend close cooperation with the Reaserch & Development Department.
Contract services

Extraction

In our production plants, we use three layers process tanks made of 316L steel (1.4404) for extraction of active substances from botanical raw materials. All of extraction tanks have an opening bottom that allows easy removal of the used post-extraction bed. The entire extraction zone is also designed to work with ethanol solutions, thus it comply with ATEX directive.

  • 2 extractors with a capacity of 6m3, equipped with agitator (115 rpm.);
  • 2 extractors with a capacity of 2m3, equipped with agitator (100 rpm.);
  • 2 extractors with a capacity of 2m3;
  • Possibility of working with bottom sieve or decanter;
  • Automatized control of water/ethanol parameters during solvent preparation for extraction (volume, temperature, pH, ethanol concentration);
  • Controlled and constant temperature during the extraction process, thanks to the heating jacket cooperating with the PID regulator;
  • Possibility of extraction at 20-90°C, with recirculation of condensated vapors and through the oil separator;
  • Percolation with flow of 5-30m3/h;
  • Osmotic water used for extraction with a conductivity of <10 μS/cm;
  • Possibility of extraction with 10-80% (v/v) ethanol solutions;

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Contract services

Separation

The separation processes carried out at Greenvit plants can be divided into two areas: - the first is the process of separating the raw material from the extract, - the second area is the separation of active substances contained in extracts from "ballast" substances (mainly sugars, naturally occurring in raw materials).

  1. Separation of the raw material from the extract by means of bottom sieves and a strainer filter module (300 μm) – ensures preliminary clarification of the extract, catches small particles of the raw material (dust) which may be present in the raw material;
  2. Decanter – an alternative to sieves and a strainer filter module is a decanter (decanter centrifuge). In this case, the aqueous suspension of the raw material (extract including the raw material) is pumped directly to the decanter, which ensures maximum recovery of the extract;
    • Centrifugal force ~3150 xg allows maximum recovery of the extract from the raw material;
    • Possibility of quality control of decantation using the “impeller” skinning disc;
    • Possibility of obtaining the water conten in spent raw material at a level below 50% (for comparison, after standard separation on bottom sieves, these vaules can reach up to 200%);
  3. Filter press – used most often together with diatomaceous earth in order to reduce the turbidity of the extract as much as possible. The liquid (filtrate) after the press is clear.
  4. Adsorption column module – allows the separation of active compounds from ballast substances. The module consists of two columns and four tanks. The module is equipped with an absorbance sensor, density measurement, flowmeter.

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Contract services

Concentration

Liquid ethanol or aqueous extract is concentrated by evaporation of water or ethanol. Concentrated botanical extract is obtained, which can be the final form of the product (dense/soft extract). If the final form of the product is powder the concentrated extract is transferred to the spray dryer unit. All evaporators comply with ATEX directive, thus can work with water or ethanolic extracts.

  1. Falling film vacuum evaporator – a solution dedicated for continuous evaporation under reduced pressure.
    • The source of energy necessary for the evaporation of water is steam which is also under reduced pressure. Thus, the heating medium supplying the installation has a temperature of 45-65°C (water vapor pressure 0.1-0.25 atmospheric pressure). By using an energy source with such a low temperature, we are sure that all thermolabile active substances will be preserved;
    • Water evaporation capacity ~1500 kg/h;
    • The density sensor on both the product and the condensate continuously provides information about the evaporation streams (especially handy during evaporation of ethanolic extracts);
    • Possibility of concentration at a pressure below 100 mbar, resulting in the fact that the temperature of the evaporated extract does not exceed 40 °C;
  2. Conical vacuum evaporator – batch type evaporator.
    • Equipped with a low-speed scraper type agitator, it allows the evaporation of water/ethanol from high viscosity extracts;
    • Possibility of evaporation at a pressure of 50-150 mbar abs;
    • Water evaporation capacity ~200 kg/h;
  3. Two-effect vacuum evaporator – the second stage of evaporator use vapors for the first stage to supply the energy necessary for phase change. This approach minimizes the energy necessary to evaporate water/ethanol from the extract
    • Possibility of evaporation at a pressure of 150-250 mbar;
    • Water evaporation capacity ~650 kg/h;
  4. Pilot scale vacuum evaporator – batch type, equipped with a scraper stirrer
    • Possibility of evaporation at a pressure of 100-150 mbar;
    • Water evaporation capacity ~80 kg/h;

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Contract services

Drying

The most stable and easiest to store is the powdered form of the extract. At Greenvit, we use a vacuum belt dryer or a spray dryer to carry out this process. In the case of spray drying, the product is sprayed in the form of a mist (maximum increase of the heat transfer area) then is mixed with the stream of hot air.

  1. Spray dryer with evaporation capacity 300 kg/h;
    • Inlet temperature 150-220°C;
    • Outlet temperature 70-110°C;
    • 15500 rpm spray disc;
    • Air brush inside the dryer chamber – equipped with filters and heaters. This device removes powder deposits from the walls of the dryer (speed of 2 rpm). The powder which could remain in the dryer is continuously removed from the walls and cone, which eliminates the possibility of burning particles (powder that has been in the dryer for too long can be different color and is easily seen in the bulk);
    • Pneumatic transport installation – the powder received under the cyclones of the spray dryer is transported by the dried air at a temperature of 40 ° C, thus the powder leaving the dryer has a low temperature;
  2. Spray dryer with evaporation capacity 100 kg/h;
    • Inlet temperature 150-220°C;
    • Outlet temperature 70-110°C;
    • 18000 rpm spray disc;
    • Pneumatic transport installation – the powder received under the cyclones of the spray dryer is captured by the dried air at a temperature of 40 ° C, thus the powder leaving the dryer has a low temperature;
  3. Vacuum belt dryer with evaporation capacity of 35 kg/h;

The evaporation occurs under the reduced pressure (10-30 mbar abs), the dense extract is sprayed on belts that move over hot stainless steel plates. The source of energy is hot water (the temperature of water can be adjusted). The process of evaporation is very gentle the temperature of the product does not exceed 40°C and there is a possibility of drying slurry products.

  • The dryer has three sections, in each section the temperature can be determined independently, as a standard, the first two sections provide the energy that drives the evaporation process, and the third section cools the powder to room temperature, this is especially important in cases of hygroscopic powders;
  • The feed speed of the belt is also adapted to the product, thus each product can have a minimum residence time inside the dryer.

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Contract services

Quality Control / Standardization

The powder products can be directly packaged or mixed with additives and/or divided into fractions according to particle size. In our plants we have:

  • Double cone mixer;
  • Ribbon mixer;
  • Grinder equipped with a different sieves;
  • Double deck vibrating control screeners;
  • Metal detector.

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