Revolutionizing Supercritical CO2 Extraction: Unlocking Scalable, Cost-Effective Solutions for Industrial Applications

Supercritical CO₂ has proven efficacy as a solvent for nonpolar compounds. However, reliance on laboratory-scale methodologies has hindered its scalability and industrial feasibility. We present test data gathered using a patented, industrially-oriented supercritical CO₂ extraction machine, showcasing revolutionary advancements in scalability, cost-effectiveness, and operational efficiency.

We will demonstrate the efficacy of our novel extraction system that enables near-instantaneous phase changes of CO₂, eliminates pre-processing requirements, and produces a compressed raffinate puck, minimizing cleanup while enabling repurposing for other applications. This system aims to simplify workflows, reduce energy consumption, and provide a scalable solution for industrial applications by addressing these operational challenges.

Our research spans 91 tests on various hops varieties, including Chinook, Cascade, CTZ, Magnum, Southern Cross, Perle, Crystal, Centennial, and Nugget, conducted since October 2021. The system has undergone over 5,000 operational cycles, processing over 500 kg of hops. Initial trials achieved a 55% extraction efficiency, while ongoing optimization has increased this average to 72%, with peak efficiencies reaching 82%. Notably, during an industrial client's commercial sample run in August 2024, 93 kg of hops were processed, achieving a remarkable 95% recovery of alpha and beta acids in the primary collection (C1).

Our system's innovative design enables continuous operation at industrial scale without compromising extraction precision or reproducibility. Unlike traditional scaled-up laboratory techniques, our approach offers enhanced throughput while maintaining energy efficiency and reducing solvent usage. These results demonstrate the potential to revolutionize supercritical CO2 extraction for a range of industrial applications, including the food, beverage, and pharmaceutical industries.
This work addresses the pressing need for scalable, high-efficiency extraction systems with significant sustainability and cost-reduction implications. Our findings will provide AOCS members with insights into cutting-edge developments in supercritical CO₂ extraction, paving the way for expanded applications.