Production process:
The key steps in the production of plant extracts are as follows:
Preprocessing:
Key steps in the production process of plant extracts, the following is a more detailed description and some specific data:
Cleaning plant raw materials:
Cleaning method:Plant raw materials are usually first carefully washed in running water to remove impurities, soil and microorganisms attached to the surface . Cleaning can use physical methods such as mechanical stirring and vortex cleaning, or food-grade cleaning agents can be used to ensure thorough cleaning.
Cleaning time:Cleaning time is usually 15 minutes to 30 minutes, depending on the type of raw material and the degree of contamination.
Cleaning temperature:The temperature of the cleaning water is usually between 10°C and 25°C to ensure that the plant material is not damaged the quality of.
Drying:
Drying methods: Drying can be done using different methods such as air drying, sun drying or heat drying. Heated drying usually uses an oven or drying equipment, and the temperature can be controlled between 40°C and 60°C to ensure that the raw materials are dried quickly and evenly.
Drying time: Drying time depends on the moisture content and type of raw materials, usually 4 hours to 24 hours.
Moisture content control: The goal of drying is to reduce the moisture content of plant materials to a safe level, usually between 5% and 10% to prevent microbial contamination and degradation.
Crush:
Pulverizing equipment:Pulverizing usually uses equipment such as grinders, cutters or jaw crushers to break down the raw materials into suitable particle size.
Particle size:The size of the crushed particles depends on the extraction requirements, usually between 0.1 mm and 5 mm. Specific particle size may vary based on different extraction methods.
If you have any questions about the content here, you can contact us at any time
Extract
Select extraction solvent:
Basis for selection of extraction solvent:The selection of extraction solvent depends on the nature and solubility of the target substances contained in the plant raw materials. For example, water is usually used to extract water-soluble components such as polysaccharides and phenolic compounds, while ethanol or aqueous ethanol solutions are suitable for extracting fat-soluble components such as oils and flavors.
Solvent concentration:The concentration of the solvent typically ranges from 5% to 95%, depending on the characteristics of the target. More concentrated solvents may provide greater solubility, but cost and safety considerations need to be considered.
Control extraction conditions:
Solid-liquid ratio:The solid-liquid ratio refers to the ratio of raw materials to extraction solvent. Generally, a higher solid-to-liquid ratio increases the concentration of the extract, but may also require more solvent. The solid-to-liquid ratio is usually between 1:1 and 1:10, depending on the raw material and extraction method.
Extraction temperature:The choice of extraction temperature depends on the stability of the target substance. Typically, extraction temperatures are between 25°C and 70°C, but for heat-sensitive ingredients, lower temperatures may be required.
Extraction time:Extraction time depends on the type of extract and solvent, usually between 30 minutes and 24 hours. Prolonged extraction can improve the extraction rate, but may also lead to the degradation of some components.
Select extraction method:
Water Extraction (Decoction): This is a traditional extraction method that is generally suitable for water-soluble ingredients. The raw materials are usually boiled in water and then filtered to separate the extract.
Alcohol extraction method (reflux extraction method):This method uses organic alcohols (such as ethanol) as the extraction solvent and is suitable for in fat-soluble components. Extraction is usually performed in a reflux device to control temperature and circulate the extraction liquid.
Subcritical extraction method:Subcritical extraction uses subcritical fluid as a solvent and is suitable for the extraction of fat-soluble components, usually in performed at lower temperatures and pressures.
Supercritical extraction method:Supercritical extraction uses a supercritical fluid (usually carbon dioxide) as a solvent and is suitable for volatile substances and extraction of heat-sensitive components, operating under supercritical conditions.
Separate or filter:
Solid-liquid separation equipment: Generally, equipment such as filters or centrifuges can be used for solid-liquid separation. The pore size of the filter membrane is usually at least 200 mesh, which can effectively remove undissolved solid particles to obtain a clearer liquid extract.
Separation efficiency:Separation efficiency is usually controlled by the pore size of the filter membrane and the filtration time to ensure complete separation of solid particles to obtain Pure liquid extract.
Purification or enrichment:
Macroporous adsorption resin: Macroporous adsorption resin is a commonly used purification method that can selectively adsorb specific components. . During purification, the extract is typically passed through a column containing an adsorbent resin that selectively captures the target components.
Recrystallization: Recrystallization is another purification method that re-crystallizes dissolved components by controlling temperature and solvent concentration. , thereby isolating target compounds with higher purity.
Condensation:
Concentration methods: For liquid or paste products, different concentration methods can be used, such as vacuum concentration, rotary evaporation or spraying dry. These methods concentrate the product to the desired concentration by controlling temperature and vacuum.
Concentration rate:The concentration rate depends on the initial concentration of the product and the desired final concentration. By controlling operating conditions, different concentration rates can be achieved.
Drying:
Drying Equipment:Drying is usually performed using equipment such as ovens, spray dryers, or vacuum dryers. Air inlet temperature, air outlet temperature and feed rate all need to be precisely controlled to ensure the product has the proper moisture content and quality.
Drying Time: Drying time depends on the nature of the product and the required moisture content. Typically, drying time ranges from a few hours to a few days, depending on the product.
Detection steps:
Target content detection:First, the target content in the extract must be detected. This can be achieved through various analytical methods such as high performance liquid chromatography (HPLC), gas chromatography (GC), mass spectrometry, etc. These methods can accurately determine the concentration of a target substance to ensure it meets product specifications.
Solvent residual detection: In addition to the target content, it is also necessary to detect the solvent residual amount in the extract. This is to ensure that solvents used during the extraction process, such as ethanol or carbon dioxide, do not exceed safe limits in the final product. The detection of solvent residues usually uses gas chromatography-mass spectrometry (GC-MS) and other methods.
Microbiological testing:For certain applications, such as food and pharmaceuticals, microbial testing is also necessary. This includes testing for bacterial, mold and other microbial contamination to ensure the microbiological quality of the product meets safety standards.
Heavy metal and hazardous substance detection:For some hazardous substances, such as heavy metals (such as lead, mercury, cadmium) and pesticide residues , also need to be tested. Excessive amounts of these substances may have adverse effects on human health.
Testing standards and regulatory compliance:
During the testing process, compliance with national and regional food safety standards and regulations must be ensured. These standards and regulations establish upper limits for target substances, safety limits for solvent residues, and allowable amounts of other hazardous substances. Products must comply with these regulations to ensure their safety and compliance.
Quality control and records:
During the testing process, quality control procedures should be established to ensure the accuracy and repeatability of testing. Test results must be recorded and compared to product specifications to determine if the product is qualified. These records are often part of production quality control to ensure consistent product quality.
Summary:
Inspection is an essential step in the plant extract generation process, which guarantees the quality and safety of the final product, making it suitable for a variety of applications . Greenskybio strictly implements the highest standards of processes to ensure quality and purity.
If you need to know the specific product process, please click here to contact our experts.
