Executive Summary
A leading nutraceutical manufacturer required a fully automated, GMP-compliant Garlic Extract Manufacturing Plant capable of producing Stabilized Allicin Powder, Aged Garlic Extract (AGE), Garlic Oil, Garlic Oleoresin, and standardized garlic extracts for domestic and international markets.
The customer required a turnkey processing facility capable of preserving heat-sensitive sulfur compounds, maximizing allicin yield, minimizing oxidation, reducing solvent and utility consumption, and consistently producing export-quality products meeting USP, EP, BP, IP, WHO-GMP, and international nutraceutical standards.
MECH O TECH LLP successfully designed, engineered, manufactured, supplied, installed, and commissioned a 20 TPD Garlic Extraction Plant integrating raw material preparation, enzymatic conversion, controlled extraction, solvent recovery, vacuum concentration, stabilization, drying, and intelligent PLC-SCADA automation.
The facility consistently produces premium garlic-derived ingredients with high allicin activity, excellent stability, superior purity, and exceptional manufacturing efficiency.
Customer Background
The customer supplies garlic ingredients to nutraceutical companies, pharmaceutical manufacturers, dietary supplement brands, functional food manufacturers, herbal medicine companies, food ingredient manufacturers, veterinary product companies, and international ingredient exporters. The growing global demand for natural immunity boosters, cardiovascular health supplements, and botanical ingredients led the customer to establish a modern automated manufacturing facility.
Customer Challenges
Before modernization, the customer faced:
- Rapid degradation of allicin
- Poor extraction efficiency
- Oxidation during processing
- High solvent consumption
- Manual production inconsistencies
- Long production cycles
- High operating costs
- Inconsistent export quality
- Limited production capacity
Project Objectives
MECH O TECH LLP developed a turnkey solution capable of:
- Processing 20 MT/day of Fresh Garlic Bulbs
- Producing stabilized allicin extracts
- Manufacturing aged garlic extract
- Producing garlic oil and oleoresin
- Preserving bioactive sulfur compounds
- Recovering over 99% extraction solvent
- Reducing energy consumption
- Meeting GMP, HACCP, WHO-GMP, USFDA, and international nutraceutical standards
- Supporting expansion up to 100 TPD
Raw Material
- Botanical Name
- Allium sativum
- Common Name
- Garlic
- Plant Part Used
- Fresh Garlic Bulbs
- Daily Processing Capacity
- 20,000 kg/day
Finished Product
Available Options
Applications
- Immunity Supplements
- Cardiovascular Health Products
- Herbal Capsules
- Tablets
- Functional Foods
- Sports Nutrition
- Veterinary Supplements
- Pharmaceutical Formulations
Process Flow
Process Description
Raw Material Preparation
Fresh garlic bulbs are washed, peeled, inspected, and crushed under controlled hygienic conditions to activate the natural enzyme Alliinase, initiating conversion of Alliin into Allicin.
Enzymatic Conversion
The crushed garlic is held under carefully controlled temperature and pH conditions to maximize allicin formation before extraction.
Advantages include:
- Maximum allicin generation
- Improved extraction efficiency
- Higher biological activity
- Consistent product quality
Low-Temperature Extraction
Extraction is performed using food-grade hydro-alcoholic solvents under low-temperature conditions to preserve volatile sulfur compounds and minimize degradation.
The extraction process ensures:
- High allicin recovery
- Excellent antioxidant preservation
- Reduced oxidation
- Uniform extraction efficiency
Filtration
The crude extract passes through multi-stage filtration to remove insoluble solids and improve downstream purification.
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 production cost
- Reduced environmental impact
- Enhanced process safety
- Superior product purity
Vacuum Concentration
The extract is concentrated under controlled vacuum conditions to preserve allicin, sulfur compounds, flavonoids, and antioxidant activity.
Purification & Standardization
Advanced purification systems standardize the extract according to customer requirements.
Typical standardizations include:
- Allicin Content
- Alliin Content
- SAC (S-Allyl Cysteine) for Aged Garlic Extract
- Total Organosulfur Compounds
- Polyphenols
- Moisture
Drying
Depending on customer requirements:
- Spray Drying
- Vacuum Drying
- Freeze Drying (Premium Grade)
The drying system ensures:
- High allicin retention
- Excellent flowability
- Long shelf life
- Superior stability
Quality Standardization
Each production batch is analyzed for:
- Allicin Content
- Alliin Content
- S-Allyl Cysteine
- Total Sulfur Compounds
- Moisture
- Residual Solvent
- Heavy Metals
- Microbial Limits
- Bulk Density
- Particle Size
Major Equipment Supplied
- Garlic Washing System
- Automatic Garlic Peeler
- Garlic Crusher
- Enzymatic Conversion Reactors
- Stainless Steel Extraction Vessels
- Pressure Leaf Filters
- Vacuum Evaporators
- Solvent Recovery System
- Purification Columns
- Spray Dryer / Freeze Dryer
- Ribbon Blender
- Storage Tanks
- PLC-SCADA Automation Panel
- Electrical MCC
- Instrumentation Package
- CIP/SIP System
Automation Features
The plant incorporates intelligent PLC-SCADA automation featuring:
- Automatic Recipe Management
- Enzymatic Reaction Control
- Temperature Monitoring
- pH Monitoring
- Solvent Flow Monitoring
- Vacuum Control
- Dryer Automation
- Batch Traceability
- Alarm Management
- Production Analytics
- Utility Monitoring
- Remote Diagnostics
- Industry 4.0 Connectivity
GMP & Safety Features
The plant is engineered according to international pharmaceutical and nutraceutical manufacturing standards. Features include:
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- Closed-loop extraction system
- Explosion-proof solvent handling
- Nitrogen blanketing
- Food-grade elastomers
- CIP & SIP compatible systems
- Validation-ready equipment
- GMP-compliant layout
- HACCP-ready engineering
Plant Utilities
- Steam Boiler
- Chilled Water System
- Cooling Tower
- Vacuum System
- Air Compressor
- RO Water System
- Soft Water System
- Electrical Power
- Nitrogen System
Sustainability Features
The plant incorporates environmentally responsible engineering through:
- Closed-loop solvent recovery
- Low-temperature extraction
- Heat recovery systems
- Energy-efficient vacuum evaporation
- Water conservation
- Reduced emissions
- Utility optimization
- Sustainable manufacturing practices
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher allicin recovery
- Improved product stability
- Superior extract purity
- 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 nutraceuticals, pharmaceuticals, botanical extracts, essential oils, food ingredients, and specialty herbal products. With over 30 years of engineering expertise, our advanced extraction technology, solvent recovery systems, low-temperature processing, and PLC-SCADA automation enable customers worldwide to manufacture premium botanical ingredients with exceptional productivity and international quality standards.
Conclusion
The Garlic Extract (Allicin) Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing stabilized Garlic Extract, Allicin Powder, Aged Garlic Extract, Garlic Oil, and Garlic Oleoresin. Through advanced low-temperature extraction, precision stabilization, intelligent automation, and hygienic GMP engineering, the facility delivers world-class product quality, reduced operating costs, and sustainable manufacturing performance.
Key Technical Highlights
- Raw Material
- Allium sativum (Garlic)
- Plant Capacity
- 2–100 TPD (customizable)
- Finished Products
- Garlic Extract, Allicin Powder, Aged Garlic Extract, Garlic Oil, Garlic Oleoresin
- Technology
- Enzymatic Conversion + Low-Temperature Extraction + Vacuum Solvent Recovery + Spray/Freeze 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, USFDA-ready, EU-GMP-ready, USP/EP/BP/IP-compatible process design, CE-compliant equipment
- Applications
- Nutraceuticals, Pharmaceuticals, Functional Foods, Dietary Supplements, Veterinary Products
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in botanical extraction and nutraceutical processing
- Complete turnkey execution from laboratory validation to commercial production
- Customized plants from 100 kg/day pilot systems to 100 TPD industrial facilities
- Advanced low-temperature extraction for heat-sensitive bioactive compounds
- High-efficiency solvent recovery with up to 99% recovery
- Intelligent PLC-SCADA automation with complete batch traceability
- GMP, WHO-GMP, HACCP, USFDA, and international hygienic engineering standards
- Comprehensive installation, validation, operator training, preventive maintenance, spare parts support, and lifetime technical assistance
- Proven expertise in herbal extracts, essential oils, nutraceuticals, pharmaceuticals, food ingredients, and specialty botanical 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
