Supercritical Fluid Extraction (SFE): Innovations in Green Technology for Food, Pharma & Nutraceuticals

Introduction: Why Supercritical Fluid Extraction is a Game Changer

Supercritical Fluid Extraction (SFE) is evolving rapidly as an eco-friendly and highly selective technology for extracting heat-sensitive, bioactive, and volatile compounds. With the integration of AI, automation, and smart design, modern SFE is becoming:

More versatile
Easily scalable
Environmentally sustainable

SFE is now used not just for food and nutraceuticals, but also for microbial control, microencapsulation, and green solvent-based purification.

1. Innovations in Equipment Design

Modern SFE systems are:

Modular and customizable for different batch sizes
Automated, improving precision, repeatability, and safety
Built with advanced materials that can withstand high pressure and aggressive co-solvents
Designed to integrate AI-driven optimization algorithms for enhanced process control

2. Microencapsulation Using SFE

Using Rapid Expansion of Supercritical Solution (RESS), active and coating ingredients are dissolved in CO₂ under high pressure and then rapidly expanded through a nozzle.

What Happens:

Supersaturation triggers coating deposition
Forms stable microcapsules ideal for:
Controlled release nutraceuticals
Flavors and fragrances
Pharmaceutical actives

This method protects sensitive compounds and allows targeted delivery in functional food products.

3. Microbial Inactivation with Supercritical CO₂

Based on research (Berenhauser et al., 2017):

Exposing bacteria to CO₂ at 20 MPa for 120 minutes causes:
Disruption of intracellular pH
Inhibition of essential enzymes
Accumulation of carbonic acid damaging microbial membranes

This makes SFE viable for:

Pasteurization and sterilization (e.g., human milk, dairy)
Clean label preservation

4. Novel Extraction Methodologies: The Algae Study

Study by Patil et al. (2017) extracted bio-oils from algae using SC-CO₂ and co-solvents like hexane + ethanol under the following conditions:

Pressure: 340 bar
Temperature: 80°C
CO₂ flow rate: 200–100 g/min
SSR (solid-to-solvent ratio): 12:1
Yield: Up to 31.37% algal lipids and 20–32% EPA (eicosapentaenoic acid)

Innovations:

Multi-stage separators (CS1 & CS2) for improved fractionation
Pressure/temperature tuning to increase extraction selectivity
Use of co-solvents to modulate polarity

This shows SFE’s potential in plant-based omega-3 extraction, vegan supplements, and specialty oils.

5. Challenges & Future Perspectives

Current Limitations:

Requires extensive process optimization
High energy consumption for CO₂ compression
Scaling up from lab to commercial is capital-intensive

Future Innovations:

Energy-efficient process designs
Use of alternative supercritical solvents
Integration of AI and machine learning to predict extraction efficiency
Expansion into:
Pharmaceutical purification
Renewable energy (biofuel extraction)
Low-cholesterol dairy products (e.g., cream powder)

Ongoing research is refining SFE into a smart, multi-industry, precision-driven technology platform.

Conclusion: Supercritical Fluid Extraction – Evolving Beyond Extraction

SFE is no longer just about extracting oils and essences. It now offers:

Microencapsulation tools for advanced delivery systems
Microbial control without heat or chemicals
High-yield extraction with zero solvent residues

A future-ready food consultant or process engineer can help you:

Select the right modular SFE system
Implement clean-label, green technologies
Design SOPs, safety, and control systems
Integrate with existing product development or purification lines

PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Supercritical Fluid Extraction _ New Innovations Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Contents 1. 2. 3. 4. 5. 6. # Introduction Microencapsulation Tool Microbial Inactivation Novel Extraction Methodologies Challenges & Future Perspective Reference About PMG Engineering Build World-Class Food Factories 2 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 1. Introduction • The innovations in SCF technology leads to improvement in extraction using, - Enhanced Equipment Design, - Novel Extraction Methodologies, And - Advanced processing techniques • As SCF technology is very specific, researchers working hard to explore new possibilities for extracting a wide range of compounds with greater and efficiency, sustainability. selectivity, Build World-Class Food Factories 3 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 1. Introduction (Cont.) a. Advancement in equipment design have improved efficiency and versatility. • Modular and customizable systems offer flexibility for different sample sizes and types. • Automation and control systems streamline operations, improving reproducibility b. Materials science advancements have improved durability and safety, allowing for handling aggressive solvents and higher operating pressures, expanding the range of applications for SFE technology. Build World-Class Food Factories 4 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 1. Introduction (Cont.) Role of SCF in different technology • Technologies using SCF as solvent i. ii. RESS Supercritical Solution) (Rapid Expansion of RESOLV (Rapid Expansion Using SCF As A Solvent Into A Liquid Solvent) • Technologies using SCF as Anti-solvent i. ii. iii. iv. v. GAS (Gaseous Anti-solvent) PCA (Particles by Compressed Anti- solvent) SAS (Super-critical Anti-solvent) ASES (Aerosol Anti-solvent Extraction System) SEDS (Solution Enhanced Dispersion into a liquid Solvent) Build World-Class Food Factories 5 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 2. Microencapsulation Tool • SFE as a microencapsulation tool for Rapid Expansion of Supercritical is a great technological Solution contribution - Dissolve active & coating ingredient - Holding SCF having solute at high pressure - Expansion through orifice or capillary device - Due to supersaturation, coating material deposited on the active ingredient followed by solvation. - Resulting capsule. formation of micro- Build World-Class Food Factories 6 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 3. Microbial Inactivation • In year 2017, Berenhauser et al., found that microbial reduction is greater at being exposed with CO2 as a solvent at high pressure of 20 Mpa for 120 min. - Reduction in intracellular/interstitial pH of bacterial cell - Deceases microbial resistance - Affect permeability of internal lipophilic functional layer with disorders due to CO2 accumulation. structural and - Inhibit or inactivate essential enzymes need by organism. - Production and bicarbonate ion leading Lethal damage to the biological system of the microbes. carbonic acid of - Extraction of vital component from the cell membrane of bacteria. Accumulation of CO2 on microbes CO2 7 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 4. Novel Extraction Methodologies • As per study coined by patil et al.(2017) on “Extraction of bio-oils from algae with supercritical carbon dioxide and co-solvents” in which extractions were carried out at 370 bar and 80 °C, then CS1and CS2 operated at 100-370 bar, 25°C and 0-100 bar, 25°C respectively. - - CS1: High pressure separator (First stage of separation) and CS2: Low pressure separator (Second stage of separation). Build World-Class Food Factories 8 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 4. Novel Extraction Methodologies (Cont.) • Experimental conditions :— - - - - Dry algal biomass powder (12% MCdb) used — 30g Reaction pressure & temperature — 200- 370 bar/ 40-80°C Reaction time — 60 min CO2 flow-rate — 200 g/min reduced to 100 g/min) • As a result, - Researchers found that yields of algal liquid to be slightly higher on increasing pressure and temperature. - Maximum total algal lipid yield (31.37% based on dry basis) observed with a. pressure 340 bar, b. co-solvent (Hexane+ Ethanol; 1:1) to algae/solid ratio (SSR) of 12:1, c. Temperature 80 ˚C and d. reaction time of 60 min under controlled CO2 flow-rate condition. - The percentage of highly valuable eico-sapentanoic acid, EPA (C20:5n3) extracted from algae were found in the range of 20- 32%. 9 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 4. Novel Extraction Methodologies (Cont.) Proces / application Process condition Effect and results References Extraction of sunflower oil from sunflower seed Sunflower seed (0.5 mm to1.00 mm) (Fluid) (Temperature) (Pressure) (solvent flowrate) – SC-CO2 + ethanol – 333 K–373 K – 20 MPa–40 MPa – 0.83 -2.50 × 10-4 kg/s Extraction of Jatropha oil (Fluid) (Temperature) (Pressure) (solvent flowrate) Jatropha seed (0.90 mm) – SC-CO2 – 50 °C – 30 Mpa – 3.23 × 10–3 kg/min Extraction of sesame seed oil (Fluid) (Temperature) (Pressure) (solvent flowrate) Sesame seed – SC-CO2 – 50 °C to 70 °C – 250 bar–350 bar – 2 ml/min Extraction yield increases with increasing pressure, solvent mass flow and co- solvent. Rai et al., (2016) Max. 51.5% oil at optimum condition with 8 fatty acid (determined by GC-MS) Mi´ci´c et al.2015 Created user-friendly Excel interface to adjust the yields of an extraction column for SCF extraction Cabeza et al., 2016 10 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 4. Novel Extraction Methodologies (Cont.) Proces / application Process condition Effect and results References Guava seed oil from guava seeds Guava seed (Fluid) (Temperature) (Pressure) (solvent flowrate) Fragrance from mangonalia Kobus Extraction of cholesterol and some other fats without removing polar fats that is liable for sensory characteristics (Fluid) (Temperature) (Pressure) (solvent flowrate) - - - - - - SC-CO2 313 K–333 K 20 MPa–35 MPa 30 g/min 40°C and 400 bar pressure. Sample: 115g dried egg yolk Extractor: Capacity 300mL Extraction (P-T-Density CO2) Separator Capacity: 103mL - - - - SC-CO2 400-550 °C 186 -713 bar 5–10 L/min Obtained max. 13.9 % w/w on the oil yield at 35.7 MPa and 325 K. Ceron et al. (2016) Cho et al. (2015) Ghosh et al., 2018 Yield was 0.27% Under extreme conditions (426 bar/55 _C), 36% of total fat and ~66% of whole cholesterol extracted Build World-Class Food Factories 11 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 5. Challenges & Future Perspective • Supercritical Fluid Extraction (SFE) offers numerous benefits, but 1. Optimization of extraction conditions is a significant challenge, requiring extensive experimentation and expertise. 2. Scalability is another significant challenge for SFE, requiring innovative engineering solutions and a thorough understanding of its principles to overcome issues with equipment design, process control, and cost-effectiveness. 3. Environmental require sustainability is major concern, as supercritical fluids like carbon energy dioxide consumption, the development of energy-efficient processes and exploring alternative solvents with lower environmental impacts. significant necessitating Build World-Class Food Factories 12 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 5. Challenges & Future Perspective (Cont.) • On future aspect, there are exciting opportunities for SFE technology. 1. Advances in automation, data analytics, and artificial the potential to optimize extraction processes and improve overall efficiency. intelligence offer 2. Additionally, there is growing interest in expanding the application of SFE to new pharmaceuticals, as fields, nutraceuticals, and renewable energy. such • Hence, Supercritical Fluid Extraction's future can holds promise due to ongoing research and innovation, enhancing equipment design, process sustainability, thereby enhancing efficiency and versatility across various industries. optimization, and Build World-Class Food Factories 13 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 6. References i. ii. x. xi. xii. Microencapsulation Mechanism Stock Vector - Illustration of beige, fresh: 135565194 (dreamstime.com) Berenhauser AC, Soares D, Komora N, Lindner JDD, Prudencio ES, et al. (2017) Effect of high-pressure carbon dioxide processing on the inactivation of aerobic mesophilic bacteria and Escherichia coli in human milk. CyTA-J Food 16: 122-126. Perrut M (2012) Sterilization and virus inactivation by supercritical fluids: A review. J Supercrit Fluid 66: 35- 371. 53. Giacomo GD, Taglieri L, Carozza P. Pasteurization and sterilization of milk by supercritical carbon dioxide treatment. University of L’Aquila, Italy. A. Cabeza, F. Sobrón, J. García-Serna, M.J. Cocero, Simulation of the supercritical CO2 extraction from natural matrices in packed bed columns: user-friendly simulator tool using excel, J. Supercrit. Fluids 116 (2016) 198– 208. xiii. A. Rai, B. Mohanty, R. Bhargava, Supercritical extraction of sunflower oil: a central composite design for extraction variables, Food Chem. 192 (2015) 647–659. xiv. V. MiC´ iC´ , S. Yusup, V. DamjanoviC´ , Y.H. Chan, Kinetic modelling of supercritical carbon dioxide extraction of sage (Salvia officinalis L.) leaves and jatropha (Jatropha curcas L.) seeds, J. Supercrit. Fluids 100 (2015) 142–145. xv. Ghosh M, Srivastava Shubhangi CJ, and Mishra HN (2018). Advent of clean and green technology for preparation of low-cholesterol dairy cream powder: Supercritical fluid extraction process. Food Quality and Safety, 2(4): 205-211. https://doi.org/10.1093/fqsafe/fyy012 xvi. H. Cho, K. Sowndhararajan, J. Jung, J. Jhoo, S. Kim, Fragrant chemicals in the supercritical carbon dioxide extract of Magnolia kobus DC. Flower buds increase the concentration state of brain function, TEOP 18 (5) (2015) 1059–1069. xvii. L.J.. Cerón, A.M. Hurtado, A.A. Ayala, Effect of pressure and temperature of extraction with supercritical CO2 on the yield and composition of guava seed oil (Psidium guajava), Inf. Technol. 27 (6) (2016) 249–258m Build World-Class Food Factories 14 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Our Clients Build World-Class Food Factories # We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients

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