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Mechotech modernizes existing extraction and distillation plants through targeted mechanical, process, utility, instrumentation and automation upgrades designed to extend asset life and improve productivity, safety, control and maintainability.
Mechotech has engineered extraction and distillation solutions since 1997, serving pharmaceutical, nutraceutical, botanical-extract, essential-oil, oleoresin, natural-colour and food-processing applications across laboratory, pilot and commercial scales and multiple extraction technologies.
What This Service Delivers
- Existing-plant technical assessment
- Bottleneck and obsolescence review
- Equipment replacement or retrofit planning
- Piping and utility modifications
- Instrumentation upgrades
- PLC/HMI modernization
- Solvent recovery and energy improvements
- Phased implementation and recommissioning
1Our Engineering Approach
Our plant modernization approach begins with the existing plant, product and process — not with a standard equipment catalogue. The engineering team assesses equipment condition, bottlenecks and obsolescence, process duties, utility constraints, control-system age, cleanability and documentation, converting this into a prioritised upgrade scope with defined duties, interfaces and phasing.
For solvent- and alcohol-based systems, special attention is given to containment, recovery, condensation, vacuum operation, compatible materials of construction and safe operating philosophy. For aqueous systems, the focus includes extraction efficiency, filtration, evaporation load, thermal exposure and downstream concentration or drying. Modifications are coordinated around production shutdown windows, and final decisions remain project-specific.
2Applications
Modernization is well suited to a range of existing-plant situations:
- Legacy extraction lines
- Manual plants requiring automation
- Capacity expansion projects
- Obsolete control systems
- Utility-constrained facilities
- Plants requiring improved cleanability or documentation
3Typical Project Workflow
A modernization project is delivered through a coordinated sequence:
- 1. Assessment: Existing-plant technical assessment.
- 2. Gap review: Bottleneck and obsolescence review.
- 3. Retrofit plan: Equipment replacement or retrofit planning.
- 4. Modifications: Piping, utility and instrumentation modifications.
- 5. Controls upgrade: PLC/HMI modernization.
- 6. Efficiency: Solvent-recovery and energy improvements.
- 7. Implementation: Phased implementation around shutdown windows.
- 8. Recommissioning: Recommissioning, verification and handover.
4Why Mechotech
- Extraction and distillation engineering focus since 1997.
- Turnkey capability across process engineering, equipment, automation, installation and commissioning.
- Experience with herbal extracts, spice oleoresins, floral extracts, natural colours, proteins, gums, resins, polyphenols and other botanical products.
- Engineering for laboratory, pilot and commercial production scales, subject to process requirements.
- Support for greenfield projects, brownfield expansion, modernization and performance improvement.
- Single technical interface across mechanical, process, piping, instrumentation and automation disciplines.
5What We Need From You
Sharing the following information helps us assess the modernization scope:
- Existing equipment list, drawings and control details.
- Current bottlenecks, constraints and obsolescence concerns.
- Target capacity, quality or efficiency improvements.
- Utility conditions and site/building information.
- Available shutdown windows for implementation.
- Solvent system and process duties.
- Final product form and specification targets.
- Applicable GMP, quality, electrical or local compliance requirements.
Frequently Asked Questions
When should an extraction plant be modernized?+
Can modernization be done in phases?+
Can old PLC systems be replaced?+
Is modernization cheaper than a new plant?+
Related Plants & Equipment
Talk to Our Engineers About Plant Modernization
Tell us about your process and target output, and Mechotech will scope the right solution for your project.
Request a Consultation