Executive Summary
A leading global manufacturer of natural ingredients required a fully automated, GMP-compliant Chlorophyll Extraction & Natural Green Color Manufacturing Plant to produce premium Natural Chlorophyll, Sodium Copper Chlorophyllin, and standardized natural green color formulations for food, nutraceutical, pharmaceutical, cosmetic, and personal care applications.
The customer required a turnkey facility capable of maximizing chlorophyll recovery, preserving pigment stability, minimizing solvent and utility consumption, and consistently manufacturing export-grade products compliant with international food safety and pharmaceutical standards.
MECH O TECH LLP successfully designed, engineered, manufactured, supplied, installed, and commissioned a 25 TPD Chlorophyll Extraction Plant integrating advanced raw material preparation, solvent extraction, pigment purification, saponification, chlorophyllin conversion, vacuum solvent recovery, spray drying, and intelligent PLC-SCADA automation.
The facility consistently produces premium chlorophyll products with excellent color intensity, superior purity, outstanding stability, and exceptional manufacturing efficiency.
Customer Background
The customer manufactures natural ingredients for food ingredient manufacturers, nutraceutical companies, pharmaceutical companies, functional food producers, cosmetic manufacturers, personal care companies, beverage manufacturers, and international ingredient exporters. Growing global demand for clean-label natural green colors and botanical nutraceutical ingredients prompted investment in a modern automated manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low chlorophyll recovery
- Pigment degradation during processing
- High solvent consumption
- Manual production variability
- Long processing cycles
- High operating costs
- Poor product stability
- Limited production capacity
- Difficulty meeting export quality standards
Project Objectives
MECH O TECH LLP developed a turnkey solution capable of:
- Processing 25 MT/day of Green Leaf Biomass
- Producing premium Natural Chlorophyll
- Manufacturing Sodium Copper Chlorophyllin
- Recovering over 99% extraction solvent
- Preserving pigment quality
- Reducing energy consumption
- Meeting GMP, HACCP, FSSC 22000, WHO-GMP, and international food ingredient standards
- Supporting future expansion up to 100 TPD
Raw Material
- Typical Botanical Sources
- Alfalfa Leaves (Medicago sativa), Spinach Leaves (Spinacia oleracea), Moringa Leaves (Moringa oleifera), Mulberry Leaves, Wheatgrass, and other chlorophyll-rich green plants
- Plant Part Used
- Fresh or Dried Green Leaves
- Moisture Content
- 10–80% (depending on feed material)
- Daily Processing Capacity
- 25,000 kg/day
Finished Product
Available Options
Applications
- Functional Foods
- Beverages
- Dietary Supplements
- Pharmaceutical Preparations
- Cosmetics
- Personal Care Products
- Oral Care Products
- Food Coloring Applications
Process Flow
Process Description
Raw Material Preparation
Fresh or dried green leaves are cleaned, inspected, dried (if required), and milled into a uniform particle size to maximize pigment extraction while preserving chlorophyll integrity.
Solvent Extraction
Prepared biomass is processed in stainless steel extraction vessels using food-grade solvents under carefully controlled operating conditions.
The extraction system provides:
- Maximum chlorophyll recovery
- Excellent pigment preservation
- Uniform extraction efficiency
- Reduced solvent loss
- Consistent batch quality
Filtration
The crude extract is clarified using pressure filtration systems to remove insoluble plant material before concentration.
Vacuum Solvent Recovery
The filtered extract enters high-efficiency vacuum evaporators where over 99% of extraction solvent is recovered, condensed, purified, and recycled.
Benefits include:
- Lower operating costs
- Improved process safety
- Reduced environmental impact
- Superior product purity
Chlorophyll Concentration
The extract is concentrated under vacuum at controlled temperatures to preserve natural pigment quality and antioxidant properties.
Purification
Advanced purification technology removes waxes, lipids, and other plant impurities, producing highly purified chlorophyll concentrate.
Chlorophyllin Conversion (Optional)
For water-soluble products, purified chlorophyll undergoes controlled saponification and copper complex formation to produce stable Sodium Copper Chlorophyllin.
Advantages include:
- Improved water solubility
- Excellent storage stability
- High color strength
- Broad food and pharmaceutical applications
Standardization
The final product is standardized according to customer specifications for:
- Chlorophyll Content
- Copper Chlorophyllin Content
- Color Strength
- Solubility
- Moisture
- Particle Size
- Stability
Quality Standardization
Finished products are analyzed for:
- Total Chlorophyll
- Chlorophyll A & B
- Sodium Copper Chlorophyllin
- Residual Solvent
- Moisture
- Heavy Metals
- Microbial Limits
- Particle Size
- Color Value
- Purity
Major Equipment Supplied
- Raw Material Cleaning System
- Dryer (Optional)
- Grinding Mill
- Stainless Steel Extraction Vessels
- Solvent Storage Tanks
- Pressure Leaf Filters
- Vacuum Evaporators
- Solvent Recovery System
- Purification Columns
- Conversion Reactors
- Spray Dryer
- Ribbon Blender
- Product Storage Tanks
- PLC-SCADA Automation Panel
- Electrical MCC
- Instrumentation Package
- CIP System
Automation Features
The plant incorporates advanced PLC-SCADA automation including:
- Automatic Recipe Management
- Extraction Sequence Control
- Temperature Monitoring
- Solvent Flow Monitoring
- Vacuum Control
- Reactor 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 and pharmaceutical manufacturing standards. Features include:
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- Closed-loop solvent handling
- Explosion-proof electrical systems
- Nitrogen blanketing
- Food-grade seals and gaskets
- CIP-compatible construction
- Validation-ready equipment
- GMP-compliant layout
- HACCP-ready process engineering
Plant Utilities
- Steam Boiler
- Cooling Tower
- Chilled Water System
- Vacuum System
- Air Compressor
- Soft Water System
- Electrical Power
- Nitrogen Supply
Sustainability Features
The plant incorporates environmentally responsible engineering through:
- Closed-loop solvent recovery
- Heat recovery systems
- Water conservation
- Energy-efficient vacuum systems
- Reduced solvent emissions
- Utility optimization
- Eco-friendly process engineering
- Sustainable manufacturing practices
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher chlorophyll recovery
- Superior pigment stability
- Improved product consistency
- More than 99% solvent recovery
- Reduced production costs
- Lower utility consumption
- Increased manufacturing capacity
- Consistent export-grade quality
- Enhanced regulatory compliance
- 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 extraction technology, solvent recovery systems, purification technologies, and PLC-SCADA automation enable customers worldwide to manufacture premium natural ingredients with exceptional productivity and international quality standards.
Conclusion
The Chlorophyll Extraction & Natural Green Color Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium Natural Chlorophyll, Sodium Copper Chlorophyllin, and natural green color formulations. By integrating advanced extraction technology, precision purification, 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
- Chlorophyll-rich green leaves (Alfalfa, Spinach, Moringa, Wheatgrass, etc.)
- Plant Capacity
- 2–100 TPD (customizable)
- Finished Products
- Natural Chlorophyll, Sodium Copper Chlorophyllin, Natural Green Food Colors
- Technology
- Solvent Extraction + Vacuum Solvent Recovery + Purification + Chlorophyllin Conversion + Spray Drying
- Solvent Recovery
- Up to 99%
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS 304 / SS 316L
- Compliance
- GMP, WHO-GMP, HACCP, FSSC 22000, USFDA-ready hygienic design, CE-compliant equipment
- Applications
- Food Ingredients, Nutraceuticals, Pharmaceuticals, Cosmetics, Functional Foods, Personal Care
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in botanical extraction, purification, and process engineering
- Complete turnkey execution from laboratory validation to commercial production
- Customized plants from 100 kg/day pilot systems to 100 TPD industrial facilities
- High-efficiency extraction with 99% solvent recovery
- Advanced purification and standardization technology
- Intelligent PLC-SCADA automation with complete batch traceability
- GMP, WHO-GMP, USFDA, HACCP, FSSC 22000, and international hygienic engineering standards
- Comprehensive installation, validation, operator training, preventive maintenance, spare parts support, and lifetime technical assistance
- Extensive expertise in natural colors, herbal extracts, nutraceuticals, essential oils, oleoresins, pharmaceuticals, food processing, and specialty botanical 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
