Chitosan Extraction

Advanced biocompatible and biodegradable polymers with multifunctional attributes are rapidly gaining traction due to their viability across biomedical and nutraceutical industries, where the application of chitosan is pivotal. Chitosan is obtained from chitin, which is one of the most important constituents of crustaceans shells. The by-product of aquatic food processing, which is a waste in the present scenario, is rich in chitin and can be sustainably managed by converting it to chitosan which serves as a value added product. Our company extracts medical grade chitosan with a high degree of deacetylation (>90%) from shrimp and crab shells, which aids in improving the functional ingredient requirements of the food industry while enabling the development of high-value nutraceuticals.

Fig 1. Chitosan as a Valuable Biomolecule from Seafood Industry Waste (Barbara E.T., 2021)

We offer a specialized chitosan extraction service aimed at the conversion of crustacean shell waste to high-value, medical-grade chitosan. This service is targeted towards food industry partners who want to utilize such additives in their products as natural antimicrobials, preservatives or functional ingredients and to those who want to explore new, high value innovative uses. Our process guarantees that the chitosan obtained will have a degree of deacetylation greater than 90% which is crucial for the medical and specialized foods sectors where purity and precise physicochemical attributes are essential.

Technical Principles

The extraction of chitosan comprises a multi-stage operation in which chitin is separated from the crustacean shells and is converted to chitosan.

• Pre-treatment: The initial step involves processing raw shrimp and crab in a manner such as thoroughly cleansing, drying, and grinding them to obtain a suitable particle size.
• Deproteinization: Using sodium hydroxide solutions at elevated temperatures, the proteins contained in the shell matrix are separated systematically.
• Demineralization: The resultant product chitin is formed as a result of the elimination of calcium carbonate as well as other mineral salts through the action of shelters which have previously been deproteinized with acidic solutions such as hydrochloric acid.

• Deacetylation: By treating chitin with a concentrated alkaline solution such as sodium hydroxide, chitin is turned into chitosan through the process of removing acetyl groups. Extended heating and treatment of the solution for long periods of time results in a rising degree of deacetylation where DD >90.% being optimal for quality.
• Purification and Drying: With the resulting chitosan, treatments such as washing, purification, and drying are performed resulting in the formation of powder and flake high purity chitosan forms.

Technical Features

• High Deacetylation: The solubility, biocompatibility, and bioactivity for the medical grade needed chitosan is consistently observed above a 90% threshold for the degree of deacetylation.
• Purity Control: High chitosan purity is attained due to having removed thoroughly proteins, materials, and other impurities.
• Controlled Molecular Weight: Although it may not be the main consideration for every application, our procedure offers some degree of molecular weight control adjustment to fit specific use criteria.
• Scalability: From pilot scale to larger production volumes, all varying demand levels can be met because of how our extraction protocols are designed for scalability.

Technical Classification

Our primary chitosan extraction technology relies on optimized chemical methods, which are well-established and allow for consistent production of high-DD chitosan. This involves sequential deproteinization, demineralization, and, crucially, a meticulously controlled N-deacetylation step using strong alkaline solutions under specific temperature and time conditions.

We are also actively exploring and integrating aspects of Green Extraction Technologies to enhance sustainability and efficiency. This includes investigations into:

• Enzyme-assisted extraction: Utilizing specific enzymes for deproteinization or deacetylation under milder conditions.
• Microwave or Ultrasound-Assisted Extraction (MAE/UAE): Employing these technologies to accelerate reaction times, reduce energy consumption, and potentially improve chitosan yield and properties.

Application Areas

• Natural Food Preservative: Due to its antimicrobial properties against a broad spectrum of bacteria and fungi, chitosan can extend the shelf-life of perishable foods.
• Edible Films and Coatings: Chitosan can form biodegradable films and coatings for fruits, vegetables, and other food products, providing a barrier to moisture and gas exchange, and inhibiting microbial growth.
• Food Ingredient Encapsulation: Protecting sensitive food ingredients, flavors, or bioactive compounds through microencapsulation.
• Clarifying Agent: Used in beverage processing (e.g., fruit juices, wine) to remove particulate matter and reduce turbidity.
• Dietary Fiber & Nutraceuticals: Its potential as a functional food ingredient with cholesterol-lowering and prebiotic effects.

Environmental Benefits

• Waste Valorization: Transforms problematic shrimp and crab shell waste, which would otherwise contribute to landfill or marine pollution, into a valuable biopolymer.
• Circular Economy: Promotes a circular economy model by upcycling byproducts from the seafood industry.
• Reduced Reliance on Synthetic Chemicals: Provides a natural alternative to synthetic preservatives and packaging materials, reducing the chemical load in food products and the environment.
• Biodegradability: Chitosan-based products are biodegradable, mitigating the long-term environmental impact associated with petroleum-based plastics.

Our Services

At our bio-environmental company, we are committed to providing more than just a product. We offer a suite of services designed to support our clients in leveraging the full potential of high-grade chitosan for their food industry innovations and high-value product development endeavors. Our goal is to be your partner in sustainability and product excellence. The services we can provide include:

• Custom Chitosan Extraction: Tailoring the extraction process to meet specific client requirements regarding particle size, viscosity, and molecular weight, while always maintaining a deacetylation degree >90%.
• Pilot-Scale Production: Offering small-batch production for research and development, product testing, and initial market trials.
• Tolling Manufacturing: Providing chitosan extraction services using client-supplied raw crustacean shell materials, processed to our exacting medical-grade standards.
• Technical Consultation: Advising on the optimal incorporation of chitosan into food products, including formulation assistance and application guidance.

• Analytical Services: Providing characterization data for the extracted chitosan, including degree of deacetylation, viscosity, moisture content, and ash content.
• Collaborative R&D: Partnering with clients to explore novel applications of high-DD chitosan and develop new chitosan-based products for the food and related industries.

Company Service Advantages

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The extraction of medical-grade chitosan from aquatic byproducts represents a significant opportunity to advance sustainability within the food industry while unlocking the potential of a versatile and highly functional biopolymer. Our dedicated chitosan extraction service provides access to premium quality chitosan and expert support, enabling our clients to develop innovative, safe, and environmentally friendly food products and high-value solutions. We are poised to be your trusted partner in harnessing the power of chitosan.

How to Place an Order

Our products and services are for research use only and cannot be used for any clinical purposes.