Mechotech evaluates operating extraction plants to identify practical opportunities for higher throughput, improved yield, better solvent recovery, lower utility consumption, shorter cycle time and more consistent product quality.
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
- Baseline data and bottleneck review
- Extraction cycle analysis
- Solvent-to-solid ratio review
- Temperature, vacuum and agitation assessment
- Filtration and concentration bottleneck analysis
- Solvent recovery performance review
- Utility and energy review
- Improvement plan and implementation support
1Our Engineering Approach
Our process optimization approach begins with the product and process — not with a standard equipment catalogue. The engineering team reviews baseline data, extraction cycle, solvent-to-solid ratio, temperature, vacuum and agitation, filtration and concentration behaviour, solvent-recovery performance and utility consumption to identify the constraints that most limit performance.
For solvent- and alcohol-based systems, special attention is given to vapour containment, condenser duty, vacuum control, evaporation conditions, leak reduction and recycle management. For aqueous systems, the focus includes extraction efficiency, filtration, evaporation load, thermal exposure and downstream concentration or drying. Recommendations are prioritised by return, risk and implementation effort, and remain project-specific.
2Applications
Optimization studies typically target one or more of the following outcomes:
- Yield improvement
- Capacity debottlenecking
- Cycle-time reduction
- Steam and cooling optimization
- Solvent-loss reduction
- Product consistency improvement
3Typical Project Workflow
An optimization study proceeds through a structured sequence:
- 1. Baseline data: Baseline data collection and bottleneck review.
- 2. Cycle analysis: Extraction cycle and solvent-to-solid ratio analysis.
- 3. Parameter review: Temperature, vacuum and agitation assessment.
- 4. Downstream review: Filtration, concentration and solvent-recovery review.
- 5. Utility review: Utility and energy consumption review.
- 6. Improvement plan: Prioritised improvement plan with expected impact.
- 7. Implementation: Implementation support for agreed measures.
- 8. Verification: Verification of results against baseline.
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
The following data is especially useful for an optimization study:
- Batch records, yields and cycle times.
- Solvent consumption and recovery data.
- Utility data — steam, cooling, electricity, vacuum.
- Operating temperatures and vacuum levels.
- Downtime and bottleneck observations.
- Quality results and specification targets.
- Equipment capacities and process flow.
- Applicable GMP, quality or compliance constraints.
Frequently Asked Questions
How can extraction yield be improved?+
Can optimization increase capacity without a new plant?+
How is solvent recovery improved?+
What data is useful for an optimization study?+
Related Plants & Equipment
Talk to Our Engineers About Process Optimization
Tell us about your process and target output, and Mechotech will scope the right solution for your project.
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