Green Tea Extract Powder - 40% - 98% by UV
Polyphenols Extraction Plants

Green Tea Extract Powder - 40% - 98% by UV

Green Tea Extract Powder

Green Tea Extract Powder - 40% - 98% by UV

Mechotech supplies the complete machinery for green tea extract powder production. Green tea (Camellia sinensis) leaves are rich in catechin polyphenols, with Epigallocatechin Gallate (EGCG) the most active. Our turnkey plant extracts, concentrates, and spray-dries these catechins into a standardised powder (commonly 50–98% polyphenols / 50% EGCG by HPLC) for the nutraceutical, functional food, and pharmaceutical markets.

Mechotech designs and manufactures the green tea extract powder extraction plant as a turnkey solution with SS 316L construction, low-temperature aqueous-ethanol extraction, integrated solvent recovery, and spray drying. The process is engineered to protect the oxidation- and heat-sensitive catechin fraction while achieving consistent EGCG assay and low moisture, meeting FSSAI, WHO-GMP, and export-grade specifications.

Manufacturing Process

1

Raw Material Preparation

Dried green tea leaves are authenticated, tested for moisture (target below 10%), and milled to 0.5–2 mm particle size to maximise solvent contact and catechin release before extraction.

2

Extraction

Milled leaves are extracted with warm water or aqueous ethanol (40–70% v/v) in closed jacketed SS 316L extractors at 50–70°C. Multiple cycles with fresh solvent maximise catechin (EGCG) recovery while limiting oxidation and thermal degradation.

3

Filtration

The extract (miscella) is clarified through a plate-and-frame filter press followed by 1–5 micron cartridge polish filters to remove leaf particulates before concentration.

4

Vacuum Concentration

The clarified miscella is concentrated in a falling-film evaporator at 50–65°C under vacuum (50–80 mbar). Greater than 95% ethanol recovery is achieved through the condenser return system, reducing operating cost and solvent discharge.

5

Standardisation & Decaffeination Option

The concentrate is assayed by HPLC for total polyphenols, catechins, and EGCG, and adjusted to the declared specification. An optional membrane or solvent decaffeination stage can be integrated for low-caffeine grades.

6

Spray Drying & Quality Control

The standardised concentrate is spray-dried to a free-flowing powder with controlled inlet/outlet temperature to preserve the catechins. Each batch undergoes HPLC assay, residual solvent, heavy metals, microbial, and moisture testing before release.

Applications

  • Nutraceutical antioxidant capsule and tablet formulations
  • Weight-management and metabolic-health supplement blends
  • Functional food, beverage, and dietary supplement manufacturing
  • Cosmetic and personal care active ingredient supply
  • Pharmaceutical standardised botanical ingredient supply
  • Export to nutraceutical ingredient buyers in regulated markets

Key Features

  • GMP-Compliant SS 316L Construction

    All product-contact surfaces are electropolished SS 316L, meeting WHO-GMP and Schedule M requirements for botanical extract manufacturing, with clean-in-place (CIP) operation between batches.

  • Catechin & EGCG Protection

    Closed low-temperature extraction and vacuum concentration at 50–65°C preserve the oxidation-sensitive catechin fraction, holding EGCG assay within the declared specification by HPLC.

  • Closed-Loop Solvent Recovery (>95%)

    Integrated condenser-distillation recovery returns greater than 95% of the ethanol per batch, cutting variable operating cost and meeting CPCB solvent discharge norms.

  • Integrated Spray Drying

    A matched spray dryer converts the standardised concentrate into a free-flowing, low-moisture polyphenol powder ready for encapsulation and blending, completing the turnkey powder line.

  • Scalable Batch Capacity

    Plants are configured from 100 kg/batch pilot scale to 2,000+ kg/batch commercial capacity, with a modular design that allows expansion without replacing core equipment.

Frequently Asked Questions

What is green tea extract powder and why is it commercially extracted?
Green tea extract powder is the concentrated, spray-dried extract of Camellia sinensis leaves, standardised for total polyphenols and EGCG catechin content (commonly 50–98% polyphenols / 50% EGCG by HPLC). It is extracted to deliver green tea's antioxidant actives in a stable, consistently dosed form for nutraceutical, functional food, cosmetic, and pharmaceutical use.
Does Mechotech supply the machinery for green tea extract powder?
Yes. Mechotech supplies the complete turnkey machinery for green tea extract powder — extraction vessels, filtration, vacuum concentration with solvent recovery, optional decaffeination, and spray drying — engineered, fabricated at our Hyderabad facility, installed, and commissioned as a single performance-verified plant.
What extraction method does Mechotech use for green tea extract powder?
Mechotech uses closed low-temperature aqueous or aqueous-ethanol extraction to recover the catechin polyphenols (including EGCG), followed by vacuum concentration and spray drying. The process is engineered around the oxidation- and heat-sensitive chemistry of green tea catechins to maximise assay and yield.
What production capacities are available for the green tea extract powder plant?
Mechotech manufactures green tea extract powder plants from 100 kg/batch pilot systems for product development to 2,000+ kg/batch commercial plants for established extract exporters. Capacity is selected based on raw material supply, confirmed buyer volume, and investment timeline, and we recommend a pilot plant to validate process parameters before scaling.

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