Pilot Plant

Our Innovation is Your Solution!

Primary Processing

Secondary Processing

Formulation


Packaging

As the product and process becoming increasingly linked along the supply-chain, our strong skill set and state-of-the-art facility will be crucial for driving the speed, efficiency, and cost-effectiveness needed for your organization and products to be innovative and competitive. The RCFFN Pilot Plant is designed for "green", cost-effective extraction and separation of bioactive compounds, the formulation of food products, formulation of controlled dose products, and the safety and stability of these products.

The RCFFN Pilot Plant is unique in that the manufacturing process can evolve from prototype through to commercial scale-up of food, nutraceuticals, or natural health products. This includes capabilities for the extraction of bio-actives from plant material or food products.

Our facility along with equipment are available for lease, with process operation completed by our technicians, or (with appropriate training) a tenant's technician.  To help you reach your goal our equipment is available for lease by the day, or a longer term contract.

Our facility is licensed as a Health Canada Natural Health Product Site and HACCP is being implemented to allow our tenants to have GMP and HACCP certified products. With a number of academic researchers on site, there is a wide range of food and natural health product expertise available.

Richardson Centre for Functional Foods and Nutraceuticals Pilot Plant is split up into four main areas:

  • Primary Processing
  • Secondary Processing
  • Formulation
  • Packaging. 

Primary Processing

Our mills offer dehulling, fine grinding, and physical air classifying separation for a variety of grains and pulses as well as a cold press system for oil extraction for oilseeds.

Satake Debranner/Rice Whitener

Designed for removing the outer bran and hull / seed coat layers from cereals and legumes (eg. wheat, barley, rye, beans, hemp etc.) by abrasion.
Capacity: Long grain 1.0-1.2 ton/hr; Short grain 1.2-1.5 ton.hr.

Prater-Sterling Fine Grinder


Designed to grind dry, free-flowing materials
Suitable for heat sensitive materials (eg. resins, sugar and powder coating etc.)

Retsch Ultra Centrifugal Mill

Maximal feed grain size: up to 10 mm
Rotor speed: can be regulated from 6,000-18,000 r.p.m.
Sieve size available: 0.08, 0.5, 0.75 mm
Cold grinding applicable

Retsch Ball Mill

Maximum feed volume: up to 300 ml
Maximum feed grain size: up to < 10 mm, but dependent on the material
Ball filling diameter: 10 mm, 20 mm, 30 mm, and 40 mm
Speed: 100 – 650 rpm

Hammer Mill

Designed to shred or crush aggregate material into smaller pieces
Equipped with a vibratory feeder
Sieve size available: 0.2, 0.5, 0.75, 2, and 4 mm

Prater-Sterling Air Classifier/Grinder

Separate materials by a combination of size, shape, and density.
Material feeding speed: 50- 250 Pounds/hr
Adjustable secondary air system for precise cuts

Sieve size available: 0.3, 0.5, 0.75, and 1 mm

Screw Oil Expeller


Cold pressing oil technology with a pressing temperature around 100 °C
Variable speed control

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Secondary Processing

Our secondary processing capabilities include the ability for green extraction from oils and meals prepared from primary processing, bioreactors for fermentation or cell culture, and filtration and distillation.

Supercritical Fluid Extraction (SFE)

Extraction of bioactive ingredients including antioxidants (eg. tocopherols, carotenoids etc.)
Removal of off-flavors from different matrices
Capacity: 1 L and 5 L extraction vessel available; Pressure up to 400 bar
Green technology: no chemical residue left in the extracts
Two collection vessels available to collect different fractions at the same time
Nozzle for fine bioactive particle formulation within the reaction vessel

Fermentation Bioreactors


Grow microbial cultures for the production of bioactive compounds or fermented food products.
Operated with controlled pH, pO2, anti-foam, temperature, and mixer speed
Self-sterilizing fermenter with a capacity of 30 L (Maximum allowable working pressure of 87 psi)

Freeze Drier


Designed for laboratory lyophilization procedures
Suitable for preservation of biological (eg. proteins, plasma, cell lines, and viruses) and the development of pharmaceuticals (eg. antibiotics)
Especially suitable for substances that are heat sensitive

Supercritical Fluid Chromatography (SFC)

Purification of small bioactive compounds using carbon dioxide as a mobile phase
Flexibility to collect up to six different fractions
Peak detection system: UV detector

Multi-purpose Processing Vessel


Designed for cooling, chilling, curing, emulsifying, reconstituting, incubating and mixing procedures for food processing
Capacity: between 10 and 15 liters

Membrane UltraFiltration

Purification and concentration of large bioactive compounds; clarification of liquid food products

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Formulation

RCFFN offers bio-product formulating and manufacturing to produce consistent natural health products to consumers.  We have an extruder and spheronizer, capsule0filing machine, and tablet press to produce products ready for market.  Specifically RCFFN provides expertise and equipment for:

Extruder & Spheronizator

Widely used in Pharmaceutical Applications

High content uniformity, smooth and coatable surface, low surface area-to-volume ratio, uniform and reproducible fill weights

Powder Blender

Used for blending and loosen up of ingredients in pharmaceutical sector

Mobile blend with a speed ranged from 10 to 50 rpm

Mixing time and speed can be individually set using the control panel

Hobart Mixer

60-quart mixer features digital smart timer, a power bowl lift and a #12 attachment hub

Four mix speeds plus stir speed

Good for mixing cake batters, mashing potatoes and developing dough

Suitable for heavy mixtures such as pizza dough, heavy batters and potatoes

Also good for incorporating air into light batches and finishing whipped items

Capsule Filling Machine

Fit size 0 capsules with 360 capsules/tray

Various auger types available: auger selection is determined by powder density and the amount of powder required. 

Tablet Press

30 stations with maximum tablet diameter 16 mm+

Maximum filling depth is 18 mm

Tablet output capacity ranged from 15,000 to 216,000/hr

Automatically or manually operation available

Piston Filler / Powder Filler

Pneumatically powered volumetric filling machine that can dispense a variety of flowable products

Products ranges from thick past (eg. spackling compound) to thin liquids (eg. alcohol)

Dispense product into containers continuously, at up to 30 containers per minute (depending on container size and product characteristics)

SD-Basic Spray Dryer

Fixed drying air volume: 70 m3/hr

Temperature ranged from 120 -250 °C

10 different pump speed available 

VFC-LAB Micro Fluid Bed

Manually operated, PLC (programmable logic controller) process controlled, self-contained fluid bed.  Used for coating and granulation or drying of a broad range of materials.

Three process air filter assemblies available, ideal for processing of small quantities:

  • Polyester Cartridge Filter Assembly
  • Polyester Flat Filter Assembly
  • Screen

Incubators and instrumentation for characterizing solubility, flowability/stability of ingredients, finished controlled dose product and food / beverage formulations. We place emphasis on quality control and inspection throughout the test process, including material verification, homogeneity testing, weight deviation measurements and package quality sampling.

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Packaging

RCFFN has an on-site supplement bottling and labelling line that allows you to put your product directly on retail shelves.


Packaging Line


Consists three main components: tablet/capsule counting machine, kalish torqit retorquer and labeling machine
Automatic and accommodates various bottles.

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