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Manufacturing Process
 
Sun Chlorella A Manufacturing Process
 
Introduction
1.Introduction
 
Our constant desire to bring you products of the highest quality is practiced throughout all manufacturing process.
 
At each process we carry out rigorous inspections based on manufacturing criteria and standards.
Introduction
 
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Slant culture
2.Slant culture
 
Slant culture
After transferring preserved strains of the Chlorella pyrenoidosa (SUN CHLORELLA strain) species to slant cultures, they are placed under artificial light and allowed to multiply under optimum temperature conditions.
 
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Flask culture
3.Flask culture
 
Chlorella propagated in slant cultures is transferred to flasks, which are placed under artificial light and supplied with air containing carbon dioxide. The chlorella cells divide while performing photosynthesis. Each time the chlorella in the liquid culture medium rises to a certain concentration, it is transferred to successively larger flasks where culturing continues.
Flask culture
 
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Seed culture
4.Seed culture
 
Seed culture
Chlorella grown indoors is moved outdoors, where culturing in the natural environment begins. The chlorella continues propagating under the sunlight in circular concrete pools with agitators. As the concentration rises, the chlorella is moved to successively larger pools.
 
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Main culture
5.Main culture
 
Main cultureWhen seed cultures are ready, the chlorella is transferred to main culture pools, which are 36 meters in diameter. The agitators in these circular concrete pools constantly stir the cultures to ensure maximum exposure to sunlight. Culturing in these pools is carried out by carefully controlling the feed amount of culture medium (the nutrient for chlorella cells) in accordance with weather conditions. Water used in the culture pools is groundwater that originates in mountains over 3,000 meters high. In addition to its stable quality and amount, this water is free of contaminants and has low hardness.

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Filtering, Dehydration, Washing and Concentration
6.Filtering, Dehydration, Washing and Concentration
 
Filtering, Dehydration, Washing and Concentration
Chlorella grown in the main culture pools is harvested after attaining the prescribed concentration. To begin with, we filter out foreign matter that enters the pools during culturing and then repeat the steps of dehydration by centrifugal separators and washing. The chlorella is then filtered, and finally it is concentrated after we are sure it is clean enough.
 
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Cell wall pulverization
7.Cell wall pulverization
 
Cell wall pulverizationThe cell wall pulverization manufacturing method developed by Sun Chlorella solved the problem of poor digestibility because of the tough cell wall, which was considered a fatal barrier to chlorella's digestion by humans. This was accomplished with the DYNOR-Mill a machine that physically breaks down the rigid walls of chlorella cells. Small and hard spheres inside the mill's cylinder are agitated with liquid chlorella concentrate by agitator blades, which cause a partial pressure difference to arise in the fluid. Cell walls are broken when chlorella cells instantly move from the high-pressure area to the low-pressure area, rapidly expand, and burst.

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Sterilization and Chlorophyllase deactivation
8.Sterilization and Chlorophyllase deactivation
 
Sterilization and Chlorophyllase deactivation
Chlorella contains an enzyme called chlorophyllase that produces pheophorbide, a substance that causes photohypersensitivity. This process deactivates chlorophyllase and sterilizes the chlorella by mixing steam into the chlorella concentrate to accomplish quick high-temperature treatment.
 
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Drying
9.Drying
 
Raw chlorella readily decomposes, but it stabilizes when dried and can be preserved for a long time. In general, the spray-drying method is widely used to dry chlorella. A concentrated chlorella solution is sprayed into a hot air steam, becoming small droplets that dry instantly. The result is dried chlorella in powder form having a vivid green seaweed or powdered green tea. Powdered chlorella is very stable and if preserved under suitable conditions will suffer no decline in quality even after several years.
Drying
Drying
 
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Tableting, Packing and Labeling
10.Tableting, Packing and Labeling
 
Tableting, Packing and LabelingSun Chlorella "A" is manufactured based upon good manufacturing practice (GMP) used for the production of medicine so as to provide reliable products people can use with assurance. Tablets and granules are made by processing chlorella powder with press machines and other devices. At each stage in the manufacture of these products we perform component analysis and conduct inspections on visual appearance, weight, contaminants, bacteria, and physical characteristics. Rigorous quality control is ensured by our own standards for important chlorella components, which are stricter than government standards, and by double-checking our products both in-house and at public institutions. Tablets and granules that pass these inspections are then packaged in aluminum, thereby completing Sun Chlorella "A" - a health food product of the highest quality. As this shows, our everyday efforts to provide very safe and high-quality Sun Chlorella "A" for improving the health of people around the world actually entail a series of rigorous steps for the control of production, manufacturing, and quality.

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Productization
11.Productization
  Patented product Japanese patent No. 3143636 U.S. patent No. 5330913
   
1.Introduction 2.Slant culture 3.Flask culture 4.Seed culture 5.Main culture 6.Filtering, Dehydration, Washing and Concentration 7.Cell wall pulverization 8.Sterilization and Chlorophyllase deactivation 9.Drying 10.Tableting, Packing and Labeling 11.Productization

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