Winterize - degum - crystallize

RX | MultiPurpose Reactor

System overview

Aptia Engineering offers premium Multipurpose Reactors to enhance the clarity, purity, potency, and marketability of your final products. Specially designed for industrial hemp production operations, the reactors are ideal for several sanitary processes including winterization, degumming and crystallization.

Every reactor is constructed with high quality stainless steel, and comes equipped with an industrial duty agitator driven by a C1D1 group D explosion proof motor, an efficient heat transfer dimple jacket, and a glass manway for easy process observation.

Available in three standard sizes – R30, R110, R175 – Aptia’s reactors can be configured to accommodate diverse processing requirements.

Standard Sizes

Product Tank Size Winterization Degumming Crystallization
R30
30 Gallons
R110
110 Gallons
R175
175 Gallons

**Multiple reactors can be combined to scale and expedite your process. 

A scalable multitool

The Multipurpose Reactors are specifically engineered for efficient extract refining operations. They can be configured to perform various refining processes such as winterization, degumming, and crystallization, providing your operation with a valuable multitool.

Collaborate with an engineer at Aptia to specify the Reactor equipment package that best suits your requirements.

  • Winterize
  • Degum
  • Crystallize

Winterization

The Multipurpose Reactor provides a scalable solution for separating waxes from extract. 

  • Modular equipment design and adoption of both low temperature refrigeration and liquid nitrogen cooling technology as optional configurations ensures that diverse and unique process requirements can be served.
  • Utilizing a specially designed reactor for the winterization step reduces labor requirements, reduces spillage, decreases open-air solvent handling and fire risk, and increases total lab productivity.
  • Generally, a complete incorporation and chilling cycle can be completed in 1.5 to 2.5 hours, which results in massive winterization capacity in even modestly sized reactors.

For larger capacity requirements, Aptia can provide multi-reactor systems that further reduce batch times and increase process efficiency. Nearly continuous processing can be achieved in these systems.

 

Process Overview

1. Incorporation – The reactor uses heat and agitation to thoroughly mix extract and ethanol into one homogenous solution.

2. Cooling – Chilled heat transfer media and agitation are used to rapidly and evenly cool the bulk solution to low temperatures.

3. Low Temperature Chilling – The solution can be further chilled using liquid nitrogen or a low temperature refrigeration system to ensure the best removal of the fats and waxes.

4. Filtration – The solidified fats and waxes are then easily separated from the refined extract in a filtration system such as the Aptia Dynamic Wafer Filter (DWF).

Degumming / Liquid-Liquid Separation

Degumming is the process of removing co-extracted phospholipids, sugars, proteins, and other water soluble compounds from crude extract, and is an often overlooked step in the extract refinement process.

This important processing step improves the flavor, clarity, potency, and marketability of extracts. Degumming also protects your high temperature processing equipment from fouling by washing out the majority of the char-forming water soluble material. Fouling reduces the efficiency of heat transfer equipment and can cause severe damage to precision rotating components such as gear pumps and the central wipers in wiped film distillation systems.

  • Reactors are temperature controlled, agitated and constructed with high quality stainless steel. 
  • Powerful agitators driven by explosion proof motors provide thorough and controlled mixing.
  • High-efficiency dimpled heat transfer jackets ensure precise temperature control.
  • Ample sight glasses provide immediate process visibility at multiple levels for real-time monitoring. 

In addition to extract degumming, the Multipurpose Reactors are ideal for conducting liquid-liquid separation processes such as washing, color removal, and pesticide remediation.

Process Overview

1. Incorporate – The system uses heat and vigorous agitation to quickly combine bulk extract and alkane solvent into a homogenous solution

2. React – A water solution is added to the reactor and thoroughly mixed with the heptane/extract solution to promote transfer of water soluble materials into the water layer.

3. Settle – Agitation is stopped and the two immiscible solutions are left to separate over the course of 3-30 minutes.

4. Separate – The water mixture containing the undesirable compounds is drained out of the bottom of the LLR system, and the solvent is transferred to a solvent recovery system.

Crystallization

Aptia’s Multipurpose Refinement Reactors provide a safer, faster and more consistent method for crystallizing CBD out of an alkane solution.

  • The reactor’s powerful agitation provides uniform temperature throughout the crystallization solution, which promotes tighter crystal size distribution and minimizes crystal formation on the vessel walls.
  • Real time temperature monitoring and high-quality refrigeration equipment provide accurate temperature control and predictable cooling rates.
  • Incorporation is made easy by selecting a heating and cooling temperature control unit (TCU) to rapidly temperature cycle the tank.
  • The enclosed reactor design contains flammable and toxic solvent vapor within the system, which reduces worker health concerns and the risk of fire in your facility.

Batch processing time varies depending upon procedure and selected temperature control equipment, but generally a high efficiency crystallization can be completed in approximately 3-Hrs.

Process Overview

1. Incorporation – The reactor uses heat and agitation to rapidly dissolve the extract in the solvent

2. Cooling – Agitation and recirculated liquid cooling rapidly and evenly cool the tank to low temperatures.

3. Low Temperature Chilling – The product can optionally be further chilled with liquid nitrogen or a low temperature refrigeration unit

4. Collect – Filter and separate the suspended CBD crystals from the solvent.

Key Features

  • Efficient heat transfer jacket provides optimal thermal efficiency and improved operator safety. 
  • Tank mounted agitator with C1D1 group D explosion proof motor. 
  • Non-explosion proof control panel which can be mounted outside of C1D2 zone. 
  • Premium quality stainless steel tank and frame. 
  • A variety of flammable fluid transfer, temperature control, and inert gas handling equipment can be supplied with each process system to accommodate unique process optimization. 
Aptia Multipurpose Reactor Detail

Related equipment

DWF Wafer Filter for Winterization

DWF | Dynamic Wafer Filter

The DWF is an innovative, stainless steel, modular filtration tool that combines flexible design with high surface area to boost the productivity and efficiency of your filtration processes.

Additional Information

Contact Aptia to learn more.