Cknown for its development of botanical extracts from grape marc or saffron, the company Activ'Inside, which employs 83 people in Gironde, has just started a new unit dedicated to the manufacturing of food supplements in the form of gummies (chewing gum), on its Beychac-et-Caillau site, 20 km from Bordeaux. This galenic form, described by the Pharmacopoeia, has become essential, both among children and adults, due to its attractive taste and texture. Its limit of use lies in the maximum quantity of extracts to be administered, which remains between 500 mg and 1g. Big names in food supplements, clients of Activ'Inside, have had to adapt to this strong trend in gummies. Their market share in food supplements has also increased from 10% in 2016 to 21.3% in 2021, reflecting the popularity of this dosage form among consumers.
A process inspired by confectionery
In its laboratories, Activ'Inside has been able to overcome challenges relating to the production of gummiesdrawing inspiration from processes used in confectionery. “Our sustained scientific research efforts coupled with our cutting-edge technology allow us to create effective and innovative formulas, and thus meet the expectations of our customers with food supplements in the form of gummies differentiating and high quality » continues the company. Once the formula has been validated, manufacturing continues within the large-scale production line where the gummies are prepared in liquid form and heated until thickened, to form a mixture called “coulis”, thanks to the use of pectin. This mixture is subsequently poured into molds which are available in several forms at Activ'inside, even if the so-called “dome” shape dominates, representing 80% of the market. Once poured into their polycarbonate molds, the gummies will cool in a dedicated room where the air is controlled (temperature, humidity and pressure). Once solidified, the gummies are extracted from their molds using a compressed air system (rather than tips), which prevents damage to the product. “We are the leading manufacturer of supplements foodstuffs in Europe to have invested in this system of unmolding of gummies »explains Activ’Inside. Finally, the coating stage plays a crucial role in the manufacturing process of gummies. It is made in a blender and uses a vegetable fiber, rather than the sugar used in confectionery. This coating step not only provides an extra layer for product stabilization, but also helps prevent sticking once it is packaged. The final stage of the manufacturing process gummies is the packaging in packaging chosen by the customer, ready for labeling and packaging. Activ'Inside insists that all its machines are European-made. “This quality of equipment coupled with rigorous maintenance processes allows us to minimize any technical problems and thus guarantee our deadlines”adds the company. Committed to a CSR approach, it has placed the development of its activities within a sustainable framework, both in terms of environmental impact and its social policy. “The construction of the site was designed to limit our environmental impact as much as possible and achieve a high level of energy performance, in particular through an innovative waste recovery system. heat and by the installation of 1,000 m² of photovoltaic panels »specified Stéphane Rey, co-founder of Activ'Inside, with David Gaudout and Benoît Lemaire.
Note, finally, that this new unit, with a capacity of 280 kg/hour, operating under standards inspired by pharma, is part of a broader investment of 13 million euros which has enabled the industrialist to build a new 3,500 m² building, opposite its historic headquarters. In addition to the production of gummiesits know-how extends to the manufacture of premixes (mixtures) of capsules and the putting into pill bottles, sticks or doypacks.
From subcritical water extraction to industrial scale
At the same time, Activ'Inside completed an investment of 2.5 million euros for the installation of a pilot and an industrial subcritical water extraction unit, in the premises of the Industrial and Scientific Hub of Cestas (Gironde) from VDLV, a French player in vaping, specializing in the extraction of nicotine from tobacco leaves. Thanks to important academic collaborations, the company was able to develop its own process and technology with a French equipment manufacturer, installing a set of tanks from 2 liters to 2,500 liters, some of which can withstand up to 5 bars of pressure and up to 'at 170°C temperature. “The complexity was being able to agitate water and plant matter under pressure”summarizes David Gaudout. This subcritical water extraction technology, which few players have mastered, makes it possible to improve extraction yields, avoid the use of solvents (ethanol, hexane), while having good economic performance. . It was not voluntarily patented to allow Activ'Inside to keep its manufacturing secrets.
With these two investments, and resources allocated to R&D representing 20% of its turnover, positioning it at the same level as pharma, the company foresees significant developments in the United States, as in Asia, on markets where the maintenance of good health through food supplements is already well established. The company plans in particular to open offices in the United States in 2025. Since its beginnings, Activ'Inside has continued to focus its strategy on the development of characterized and objective products, such as its flagship active ingredients Memophenol, a source of polyphenols. for the prevention of cognitive decline, or the anti-stress Safr'Inside. As such, the company is positioned among the main patent applicants in New Aquitaine.
HOW ACTIV’INSIDE OBJECTIVES THE EFFICIENCY OF ITS ASSETSThe Mediterranean diet has long been praised for its health benefits, and researchers are now focusing on its key components to better understand their impact on aging: polyphenols and carotenoids. The result of a collaboration between Activ'Inside and the Molecules of Biological Interest team at the Institute of Vine and Wine Sciences (ISVV) in Bordeaux, the Silver PhytoNutrients project is part of this theme. It aims to comprehensively characterize the metabolic fate of nutrients, in particular polyphenols present in the Mediterranean diet. By studying the metabolic pathways of grape metabolites (but also those of saffron), the project seeks to discover the mechanisms of action and the effects of these compounds on the aging process. With the Silver PhytoNutrients project, the objective is both to acquire scientific knowledge, but also to develop new natural products adapted to the Silver Economy market.
