fracTron-100 Falling Film Distillation
The fracTron-100 is a single-stage batch falling film distillation unit for rapid solvent recovery & removal of volatiles from liquid mixtures. It supports a recycling capacity of up to 60 gallons in a continuous process batch, utilizing an air driven pump.
This version of our falling film evaporator solution is the ideal solvent removal system for entry level extractors who need a reliable solvent removal method at a reasonable price point. GMP certified stainless-steel materials support global market requirements; and the fracTron-100 can be GMP certified (optional). Chiller and heater are sold separately.
The fracTron-100 is a manual single-stage falling film evaporator that is based on the technology of our fracTron-1000. The machine contains a single stainless falling film column with independent temperature control and evaporator jacket. It is designed to provide an avenue for those looking for superior solvent removal equipment at the ground level. With the fracTron-100 you can expect outputs of 20gal per hour of refined extract. This is a great starter machine for those looking to get their feet wet into solvent removal.
Advanced Solvent Removal (Without Rotovaps)
The step of solvent removal in CBD extraction and formulation is not just important, it is essential to creating a product that is pure and safe for consumption. In this episode of extrakTALKS, Dr. Jon and Randall Thompson discuss the ongoing bottleneck of solvent removal with rotovaps and extraktLAB’s fracTron three-stage falling film evaporator solution. Listen close to the pros and cons of traditional rotary evaporators, current falling film technologies, and why the fracTron is the most cutting edge technology in solvent removal.
Manual System with Manual Control
The fracTron-100 features:
- Up to 20 gal/hr capacity
- Falling film separation
- Air driven pump
- UL listed components
- C1D2 compliant
Dimensions: 90”x44”x72” (LxWxH)
Electrical: 208-230/380V, 3 phase, 50/60 Hz
Wetted Materials: 316SS, PTFE, Silicone Rubber
Warranty: 12 months, Parts & Workmanship
Additional Services Available
GMP Equipment Documentation Package | #80-9606
Manufacturing Line Commission (GMP) | #80-9629
Maintenance (12 months) | #80-9609
Frequently Asked Questions
Can rotovaps be replaced with a falling film evaporators?
fracTron is our version of a falling film evaporator. The equipment is capable of replacing many rows of apps nearby streamlining the solvent removal process during ethanol extraction or winterization. The equipment is able to efficiently remove ethanol from the cbd oil to the point that it can be directly introduced into a wiped film evaporator.
One of the advantages to the FracTron is that it can be configured in several different ways to give it more versatility. It can be used as a 3-stage fractional distillation piece of equipment or it could be used also as a two-stage falling film evaporator and one stage decarboxylator unit for decarboxylation of oils.
Since the fraction is able to condition the oils in such a way that they can be introduced directly into a wiped film evaporator, the unit is capable of being fully integrated and automated to feed a wiped film distillation unit.
Can I feed my ethanol/extract mixture directly into the falling film?
Yes, the system is engineered to fit directly into any batch or continuous extraction process.
How does the fracTRON help reduce maintenance and automate cleaning?
The fracTRON is a continuous system, it doesn’t require disassembly between runs. When it needs to be cleaned, simply run the system with clean ethanol at 50C (in all columns). If inspection is required, remove the top two clamps to swab the surfaces.
How do you clean the fracTRON?
The system is cleaned by flushing with clean ethanol. The fracTRON has a piping manifold for even distribution of the liquid mixture which also helps to force cleaning solvent into potentially clogged tubes. The apparatus is easily disassembled for inspection.
Can I collect distillate from different stages independently?
With an optional piping package, yes. Having the ability to be set to 3 different setpoints throughout the system, select components can be evaporated and collected preferentially. This is particularly useful for industrial fractioning of terpenes.
Does the system come with methods?
Methods and formulas are delivered with the system.
Is degassing required after treatment with a falling film?
Depending on the operating conditions, degassing is still required after subjecting the extract/ethanol mixture to falling film evaporation. Degassing decreases the ethanol content of the mixture from ~10-15% from the evaporator to 2% which is required for wiped film evaporation. The time it takes to degass is largely dependent on the starting ethanol content as well.
What yield should we expect from the falling film evaporators?
Yield of plant extract is generally near 100%. Plant extracts have much higher boiling points than that of ethanol and the flow path of ethanol vapor is engineered so that if aggressive boiling of ethanol causes entrainment of plant extracts, the plant extracts are forced out of the vapor.
What is the surface area of the unit and how does that impact throughput?
Each stage contains 52 square feet of heated surface area for product evaporation. Generally, as surface area for product evaporation increases, the throughput of the system increases.
How does a falling film fit in my workflow?
Ethanol is the most common solvent for removal of fats and waxes from a plant extract and it needs to be removed from the mixture for downstream product refinement. Ratios of ethanol/winterized oil are typically between 4/1 and 10/1, high capacity falling film evaporators are necessary for large scale removal of ethanol from plant extracts.
Are solvent residuals still left in the oil after distillation?
Complete removal of solvent is hard to achieve with a single stage falling film evaporator because of the single temperature setpoint. As the liquid mixture flows through the tubes of the falling film evaporator, it changes composition due to vaporization of the volatile component. The change in composition changes the physical properties of the macroscopic mixture – including the boiling point. The fracTRON utilizes a triple pass falling film system to change the operating temperature of the evaporator as the temperature of the liquid mixture changes.
How clean is the ethanol coming from the falling film still?
Purity of product depends on many things such as temperature and flow rate of the heated media, flow rate of the liquid mixture to be distilled, pressure of the system, surface area of the heated surfaces, and mechanism of vapor-liquid separation. Depending on these conditions, most falling film evaporators remove 80-95% of ethanol from the starting mixture.
What does a falling film evaporators do?
Falling film evaporators are largely used to remove a solvent from a liquid mixture by evaporating the more volatile component. Compared to wiped film evaporators, falling film evaporators: have a higher heated surface area per footprint, are less equipped to distill highly viscous mixtures, and are much better equipped to distill a solvent at a high throughput. Falling film evaporators are vertical in orientation, and have a bundle of metal tubes in a metal container. The metal tubes are then heated with a flowing media and the heat is transferred to the liquid mixture to evaporate the volatile component as the mixture flows down the tubes. Single stage falling film evaporators have high surface area and can be set to a single temperature.
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