SDR1200 Spinning Disc Reactor for Hemp Oil Extraction and Botanical Oil Extraction
The New Revolution in Processing using Water as the Solvent
Simple push-button operation and uses only water as the carrier-solvent, this amazing system uses technology that was previously only available in the pharmaceutical industry. Process 50-100 pounds per hour, or up to 2,400 pounds (1,200 kg) per day of hemp, algae, or other botanicals. This system produces a crude oil extract, which is considered a Full Spectrum Hemp Oil extraction.
Note: Wisconsin Hemp Processors may see a payback in less than a week.
Product: The SDR1200 is a continuous feed botanicals crude oil extractor, using spinning disc reactor technology, which is well proven in the food processing and pharmaceuticals industry. The system is used in this application with water as the solvent to produce a full spectrum extraction. With further winterization processing, the resulting full-spectrum-oil is ready for sale as a concentrate.
Profits: The SDR1200 allows processing of large amounts of botanicals extraction, compared to batch reactors. This allows better processing efficiency, which saves labor and energy costs, and increases your profit potential.
Time: The SDR1200 saves you time. The continuous feed processing methodology gets you finished product faster, and at less production cost.
The Problem With Large Scale Ethanol Batch Extraction: Typically, large scale ethanol extraction has a number of drawbacks. Since recycled ethanol is imperitive to low cost processing operation, the dilution of the pure ethanol becomes compromised (water keeps getting added) which results in poor extraction efficiency. In addition, ethanol has poor turpene retention (turpepes become volatile and simply evaporate). Finally, many ethanol processors who do a quick-turn extraction, end up with lots of bitter green tasting chlorophyll. To filter out that, they use activated carbon filters (referred to as carbon scrubbing), which also filter out most of the valuable components ( source: Romano LL, Hazekamp A. Cannabis Oil: chemical evaluation of an upcoming cannabis-based medicine. Cannabinoids. 2013;7(1):1-11.)
Here is our general information on the Hydro SDR1200: No more loud air compressors, or dealing with supplies of CO2, or ethanol. No more waiting 12-24 hours for your batch processor to complete its cycle. This is instantaneous botanical oil extraction which uses water and shear force to break apart plant cells to give up their oil. Because this is a non-pressurized system and it does not use explosive hydrocarbons (i.e. like butane or propane which needs Class 1 Div 1), this system is much easier to accept for zoning, code, and inspectors. In addition, there is no danger of CO2 gas in a enclosed space, and no venting needed. You’re using water as the solvent.
Continuous Feed Eco Extraction:
We have the first system in the industry that is continuous feed. No more batch runs that take 12-24 hours. Processing is virtually instant using our fast extraction processing. More thorough and consistent extraction. Push button operation and less complex parts means less maintenance. Best of all, there are no expensive, hard to get, high pressure parts to maintain. The overall safety on a low pressure system far outweigh a butane, ethanol, or CO2 system. Simple to use, and simple to maintain.
The Problem Of Conventional Extraction Systems: Existing ethanol or CO2 systems won’t work well for large continuous feed production. Also, with lots of hemp growers and processors coming online for the production of isolate, and full spectrum hemp oil, a organic method of continuous hydro extraction is needed. Large scale CO2 reactors reactors (on a industrial scale similar to ones used for decaffeinating tea and coffee beans) are huge, expensive, and take a very long time to build and install. Big batch systems can only process one variety of a botanical at a time. Our system is disruptive technology which turns that legacy system on its side.
The Solution: Spinning Disc Reactor. Water as the solvent. The system is modular, compact, and relatively inexpensive (payback generally less than two weeks when you have market priced hemp flower acquisition and full spectrum oil buyers). It installs quickly, can be mobile, and can do continuous feed which allows rapid re-integration for using different botanicals, different varieties of botanicals.
Time is Money: The new method and equipment are so efficient that the process takes a few seconds, instead of hours or days, which is common in the industry now. In addition the system uses distilled water as the solvent, instead of CO2, butane, or large batch ethanol, which are the common extraction solvents now.
Design and Prepare for the Future: Ask any industrial user, and they’ll tell you that continuous flow is the wave of the future. With the high cost and low quality of ethanol extraction (poor terpene retention and low efficiency), and the fire codes which need to be complied with for hazardous solvents, water is the natural choice. As local and federal government put in more stringent codes in place, a non-pressurized water based system will avoid any building code issues. Plan for the future.
Other Features: Our system is also unique in that because we use a flow that is continuous, we can put in filters that automatically remove waxes or other compounds which are not desired in the final concentrate products. This type of continuous flow system is also very energy efficient. Much more energy efficient because the reaction time is in seconds, not hours or days.
Off-the-Shelf Components Used in Water Systems: Because we use water, the equipment that we use in the process to a great extent, is already available off-the-shelf. Since we use a large volume of water we want to use a closed loop system. Within that system we will need filters and particulate separators, which are already available and use the widespread in different industries. Water management has been around for thousands of years. Using water, we can avoid many of the fire code restrictions that currently exist for butane extraction systems. Because we do not use CO2, we do not have to worry about expensive pressure fittings or finding a supply of CO2. Same applies for ethanol – we do not use that solvent for the extraction process, which can save hundreds of thousands in consumables per year.
Multiple Use: The concept of a continuous feed oil extraction system is not limited to botanicals such as Hemp. This technology can also be used in other industrial applications, such as the production of biodiesel, algae oil harvesting, and in the high tech sector.
Hi-Tech Applications – Quantum Dots, Silver Nano Particles, and Graphene: Quantum dots are semi conductor nano crystals which have already been identified for the use of the replacement of silicon solar cells. They have also been identified for use in the medical industry for finding cancer. In the electronics field quantum dots can be used for making television screens, and as a potential power storage media in batteries. Graphene is made from graphite, which can be made from activated carbon (hemp or other botanical feedstock). Graphene is the highly desired material which is stronger than steel, and more conductive than copper. We are also experimenting with LIB (Lithium Ion Battery) recycling, Cobalt, and gold recovery from integrated circuit waste.
Design Goals: The overall goal with all of the design is to minimize complexity. By doing so, you can minimize maintenance, footprint, and overall initial and running costs. Coming up with an elegant, but substantially simpler design, is sometimes the most difficult. The actual SDR unit is comprised of patented Modular Blocks. Termed the Industrial Lego by the National Science Foundation, these interconnection fluid processing blocks provide rapid prototyping to commercial product in one format.
Modular and Scalable: Our organic botanical reactor is made from our patented modular blocks which are bolt-together, and can be easily upgraded or scaled up.
Dual Flow: Each system has two independent flows, so that one part of the process can be paused temporarily for maintenence. This allows the processor to operate 24/7.
Push-Button Operation: The SDR extraction system is unique in that once you have the parameters set, the operator only has to turn the system on and monitor (also done by a PLC). No need for complex recipes, computer algorithms, PLCS controlling a vexing array of valves, pressures, and temperatures, etc. This push-button system is unique to the industry, and reduces operator input into the success or failure of the process. If your operation now is dependent on its weakest link, then you’ll understand. Our PLC monitors the system, so that you have reports accessible online and by a smartphone, so you’ll have all the metrics at your fingertips.
Solar Powered Option: With continer roof mounted solar PV panels, you can make your operation remote off-grid powered, to further enhance the Eco-Extraction processing.
SDR Industrial Extractor System Pricing:
Continuous Feed System
Engineering Study For Large Processing: Prior to an official quotation on a large system, we have the customer commission a engineering study to examine the type of extraction, material, infrastructure, and system components. Typically, for small to average installations, this will be around $150,000+
SDR1200: Up to 1200 kg per day. Up to 110 lb/hr (50 kg/hr). Basic system starting at $2,000,000 USD. Complex systems can range from $3-5 million USD.
Major System Components:
A. Pre-Processing: Botanical feed.
B. Processing: Spinning Disc Reactor
C. Separation and Filtration: Separation of botanical plant matter, water, and oil. Basic filtration of water.
D. Water Storage and Conditioning: Containerized liquid storage tanks with water polishing.
Solvent: Distilled water.
Process: Closed-loop or one pass continuous flow.
Custom Build Time After Deposit: 6+ months (depending on size and order build requirements).
Tracking and Processing Management: We have developed database applications which track maintenance, operation, and product flow using Filemaker software.
SDR Goals | Process | Background
The goal of the SDR1200 is to crack open the cell (cell lysis) and empty out the contents. That crude oil extract is then collected using a centrifugal separator. We also are starting to integrate some exciting centripetal vortex separation (see our instagram site for video: https://www.instagram.com/infinitysupercritical/
The goal of the SDR1200 is to efficiently harvest oil, above 90 percent (the target with water polishing is going to be 95-98%).
Primarily in the plant cells: https://www.ncbi.nlm.nih.gov/pmc/articles/PMC3736954/
More specifically, we’re targeting the trichomes:
To do this, we’ve experimented, and found the most efficient and economical way is to blast them with a microjet, which is produced from cavitation (think of a World War II depth charge – it’s not the explosion that breaks steel, it’s the resulting 80,000 psi microjet from the cavitation of the explosion. You may be familiar with a common method of cavitation called ultrasound. Ultrasound is a sonic method of vibrating water until cavitation is produced. On a small scale it works just fine, but not for large scale continuous modes of botanical extraction. Cavitation by mechanical means (e.g. the spinning disc reactor) is a high throughput methodology to crack open the cell to release the valuable hemp oil.
This technology has already been well-proven in the pharmaceutical and food processing industry with the spinning disc reactor (you may wish to Google the subject if you wish to research it).
The fact that resins are hydrophobic is perfect. We want to easily separate them from the water after the cell is blasted apart. The SDR is not a wash-plant per se (think of washing gold in a sluice box – which is not very efficient), but rather a method to blast open cells to release oil, then those extracts are collected. In this case, after the cell is emptied of its contents, this system is like a magnet collecting the contents.
NDA: Unfortunately, we’ve learned the hard way that the cannabis industry simply ignores NDA’s, so we don’t offer that option. We only release information that is not considered confidential. And yes, this technology will really change the extraction landscape of the industry, that is why other extraction companies are trying to find out what we’re doing so they can copy it.
If you would like to see what our system can do, then I suggest commissioning a Engineering Study to test your hemp, and analyze the results. We’ll ask that you first analyze your sample as a control, then we’ll do secondary lab work prior and after extraction tests. That way you have a good indication of the process, and have your control to compare.
Prior to moving further, we’ll need some proof that you can actually afford this system, unless you move forward with the paid Engineering Study. In the past, we’ve experienced many groups who claim to have funding, but after we provided them with all the information they required, they did not have funding. This takes time away from actual paying customers.