Executive Summary
A leading natural ingredient manufacturer required a fully automated, GMP-compliant Beetroot Natural Color Extraction Plant to manufacture premium Betanin, Betalain Concentrates, and natural red food color ingredients for the food, beverage, nutraceutical, pharmaceutical, cosmetic, and functional food industries.
The customer required a turnkey processing facility capable of maximizing pigment recovery, preserving heat-sensitive betalains, minimizing energy consumption, and consistently producing export-grade natural color ingredients that comply with international food safety and quality standards.
MECH O TECH LLP successfully designed, engineered, manufactured, supplied, installed, and commissioned a 30 TPD Beetroot Natural Color Extraction Plant integrating advanced washing, slicing, aqueous extraction, enzymatic treatment (optional), membrane clarification, vacuum concentration, spray drying, and intelligent PLC-SCADA automation.
The facility consistently produces premium beetroot color concentrates with high betanin content, excellent color stability, superior purity, and outstanding manufacturing efficiency.
Customer Background
The customer manufactures natural color ingredients for beverage manufacturers, dairy companies, bakery & confectionery industries, nutraceutical companies, functional food manufacturers, pharmaceutical companies, cosmetic manufacturers, and global food ingredient exporters. Growing worldwide demand for clean-label natural red colors prompted the customer to establish a highly automated manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low pigment recovery
- Betalain degradation during processing
- High water consumption
- Variable product quality
- Long production cycles
- Manual process inconsistencies
- High operating costs
- Limited production capacity
- Difficulty maintaining export-quality color specifications
Project Objectives
MECH O TECH LLP developed a turnkey facility capable of:
- Processing 30 MT/day of Fresh Beetroot
- Producing premium Betanin concentrate
- Preserving natural betalains
- Minimizing thermal degradation
- Reducing water and utility consumption
- Meeting GMP, HACCP, FSSC 22000, ISO 22000, and international food standards
- Supporting future expansion up to 150 TPD
Raw Material
- Botanical Name
- Beta vulgaris
- Common Name
- Beetroot
- Plant Part Used
- Fresh Roots
- Moisture Content
- 75–88%
- Daily Processing Capacity
- 30,000 kg/day
Finished Product
Available Options
Applications
- Beverages
- Dairy Products
- Yogurt
- Ice Cream
- Bakery Products
- Confectionery
- Nutraceutical Supplements
- Functional Foods
- Cosmetics
- Pharmaceutical Formulations
Process Flow
Process Description
Raw Material Preparation
Fresh beetroot is thoroughly washed, sorted, peeled (if required), sliced, and crushed to increase extraction efficiency while minimizing pigment oxidation.
Aqueous Extraction
Crushed beetroot is extracted using controlled aqueous extraction under low-temperature conditions to preserve natural betalains.
The extraction process provides:
- High pigment recovery
- Excellent betanin preservation
- Uniform extraction efficiency
- Reduced oxidation
- Consistent product quality
Enzymatic Treatment (Optional)
Food-grade enzymes may be incorporated to improve juice yield, pigment release, and filtration efficiency.
Benefits include:
- Increased extraction yield
- Lower viscosity
- Improved clarification
- Reduced processing time
Membrane Clarification
The extract passes through microfiltration and ultrafiltration systems to remove suspended solids while preserving valuable pigments.
Advantages include:
- Excellent clarity
- Low-temperature processing
- Better color stability
- Reduced product losses
Vacuum Concentration
The clarified extract is concentrated under vacuum at low temperatures to preserve the natural color compounds and nutritional value.
Standardization
The concentrate is standardized according to customer requirements for:
- Betanin concentration
- Color intensity
- Soluble solids
- pH
- Stability
Spray Drying / Liquid Formulation
Depending on customer requirements, the product is supplied as:
- Spray-Dried Powder
- Liquid Concentrate
- Customized Color Blends
Quality Standardization
Finished products are analyzed for:
- Betanin Content
- Total Betalains
- Color Value
- Moisture
- pH
- Total Soluble Solids
- Heavy Metals
- Microbial Limits
- Particle Size
- Purity
Major Equipment Supplied
- Raw Material Washing System
- Sorting Conveyor
- Root Slicer
- Crusher
- Extraction Tanks
- Enzymatic Treatment Tanks (Optional)
- Microfiltration System
- Ultrafiltration System
- Vacuum Evaporator
- Spray Dryer
- Ribbon Blender
- Liquid Storage Tanks
- PLC-SCADA Automation Panel
- Electrical MCC
- Instrumentation Package
- CIP System
Automation Features
The plant incorporates advanced PLC-SCADA automation featuring:
- Automatic Recipe Management
- Extraction Temperature Control
- pH Monitoring
- Flow Monitoring
- Membrane Performance Monitoring
- Vacuum Control
- Spray Dryer Automation
- Batch Traceability
- Alarm Management
- Utility Monitoring
- Production Analytics
- Remote Diagnostics
- Industry 4.0 Connectivity
GMP & Safety Features
The facility is engineered according to international food manufacturing standards. Features include:
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- CIP & SIP compatible systems
- Automated cleaning programs
- Food-grade elastomers
- Dead-leg-free piping
- Validation-ready equipment
- GMP-compliant layout
- HACCP-ready process engineering
Plant Utilities
- Steam Boiler
- Chilled Water System
- Cooling Tower
- RO Water System
- Air Compressor
- Soft Water System
- Electrical Power
- Instrument Air
Sustainability Features
The plant incorporates environmentally responsible engineering through:
- Low-temperature processing
- Water recycling systems
- Energy-efficient membrane filtration
- Heat recovery integration
- Reduced wastewater generation
- Utility optimization
- Eco-friendly processing technology
- Sustainable manufacturing practices
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher betanin recovery
- Improved pigment stability
- Better product consistency
- Reduced water consumption
- Lower operating costs
- Increased production capacity
- Consistent export-grade quality
- Enhanced automation and traceability
- Better global competitiveness
- Excellent return on investment
Plants Used In This Project
Why Mech O Tech LLP?
MECH O TECH LLP is a globally recognized manufacturer of turnkey extraction plants for natural colors, herbal extracts, nutraceuticals, pharmaceuticals, food ingredients, and specialty botanical products. With over 30 years of engineering expertise, our advanced aqueous extraction systems, membrane technologies, low-temperature concentration processes, and PLC-SCADA automation enable customers worldwide to manufacture premium natural color ingredients with exceptional efficiency and international quality standards.
Conclusion
The Beetroot Natural Color Extraction Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium Betanin, Betalain concentrates, and natural red food colors with exceptional purity and stability. By integrating advanced aqueous extraction, membrane clarification, intelligent automation, and hygienic GMP engineering, the facility delivers world-class product quality, lower operating costs, and sustainable manufacturing performance.
Key Technical Highlights
- Raw Material
- Beta vulgaris (Beetroot)
- Plant Capacity
- 5–150 TPD (customizable)
- Finished Products
- Betanin Extract, Betalain Concentrate, Spray-Dried Beetroot Powder, Natural Red Food Color
- Technology
- Aqueous Extraction + Membrane Clarification + Vacuum Concentration + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS 304 / SS 316L
- Compliance
- GMP, WHO-GMP, HACCP, FSSC 22000, ISO 22000, USFDA-ready hygienic design, CE-compliant equipment
- Applications
- Food Ingredients, Beverages, Dairy, Bakery, Nutraceuticals, Pharmaceuticals, Cosmetics
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in botanical extraction and natural ingredient processing
- Complete turnkey execution from laboratory validation to commercial production
- Customized plants from 500 kg/day pilot systems to 150 TPD industrial facilities
- Advanced low-temperature extraction and membrane separation technology
- Intelligent PLC-SCADA automation with complete batch traceability
- GMP, WHO-GMP, USFDA, HACCP, FSSC 22000, and ISO-compliant hygienic engineering
- Comprehensive installation, validation, operator training, preventive maintenance, spare parts support, and lifetime technical assistance
- Extensive expertise in natural colors, herbal extracts, nutraceuticals, essential oils, pharmaceuticals, and food processing plants
Want Results Like This For Your Plant?
Mechotech engineers are ready to assess your process and design the right plant for your target output.
Get a Free Consultation
