As. prof. Beley N.N.As. prof. Beley N.N.Ternopil State Medical Ternopil State Medical University University

about Horbachevskyabout Horbachevsky

Soft and dry extracts Soft and dry extracts production. production.

Processes of evaporation and Processes of evaporation and drying. Equipment to drying. Equipment to

evaporation and drying. evaporation and drying.

Technological stages of soft Technological stages of soft extracts productionextracts production::

1. Preparing of production1. Preparing of production

2. Preparation of herbal raw materials 2. Preparation of herbal raw materials

(milling, sifting) and extragent(milling, sifting) and extragent

3. Obtaining of liquid extract 3. Obtaining of liquid extract

4. Purification of liquid extract4. Purification of liquid extract

5. Evaporation of solvent for extraction (extragent)5. Evaporation of solvent for extraction (extragent)

6. Standardization 6. Standardization

7. Packing, packaging and labeling of final product.7. Packing, packaging and labeling of final product.

The plans of fulfilling of the dry extracts The plans of fulfilling of the dry extracts production production ::

Evaporation stage is includedEvaporation stage is included

1. Obtaining of liquid extract 1. Obtaining of liquid extract

2. Purification of liquid extract2. Purification of liquid extract

3. Manstruum evaporation 3. Manstruum evaporation

4. Drying of slightly evaporated 4. Drying of slightly evaporated extractextract

5. Standardization5. Standardization

6. Packing, packaging and 6. Packing, packaging and labeling of final productlabeling of final product

Without evaporation stageWithout evaporation stage

1. Obtaining of liquid extract 1. Obtaining of liquid extract

2. Purification of liquid 2. Purification of liquid extractextract

3. Drying of liquid extract3. Drying of liquid extract

4. Standardization4. Standardization

5. Packing, packaging and 5. Packing, packaging and labeling of final productlabeling of final product

Methods obtaining of infusion while Methods obtaining of infusion while soft and dry extracts production:soft and dry extracts production:

1. Percolation 1. Percolation 2. Repercolation 2. Repercolation 3. 3. Bismaceration and its various modifications Bismaceration and its various modifications 4. 4. Circulating extractionCirculating extraction5. 5. Extraction of HRM in a battery of percolators with extragent Extraction of HRM in a battery of percolators with extragent

circulatingcirculating

66.. Continuous extraction with an opposite movement of HRM Continuous extraction with an opposite movement of HRM and extragent to meet each other in special extractorsand extragent to meet each other in special extractors

7. M7. Methodsethods of extraction of extraction, , includingincluding milling of raw materials in milling of raw materials in

the environment of extragent, vortex extraction, extraction the environment of extragent, vortex extraction, extraction using electromagnetic waves, ultrasound, electrical using electromagnetic waves, ultrasound, electrical discharges et al.discharges et al.

Extraction of HRM in a battery of Extraction of HRM in a battery of percolators with extragent circulatingpercolators with extragent circulating

Hot continuous Extraction (Soxhlet)Hot continuous Extraction (Soxhlet)

Soxhlet apparatusSoxhlet apparatus

1. 1. Cube for distillationCube for distillation2. Siphon tube2. Siphon tube3. Extractor3. Extractor4. Collector of 4. Collector of

condensatecondensate

5. 5. RefluxReflux -condenser -condenser

Hot continuous Extraction (Soxhlet)Hot continuous Extraction (Soxhlet)

is repeated extraction of HRM by the circulating is repeated extraction of HRM by the circulating extragent. extragent. There is the extragent in the cub and collector.There is the extragent in the cub and collector.HRM is placedHRM is placed in the extractor and is poured on in the extractor and is poured on with an extragent just below the siphon tube.with an extragent just below the siphon tube.After the imbibitions you have pass extragent After the imbibitions you have pass extragent through the raw and obtain infusion.through the raw and obtain infusion.Than you have begin to heat up the extragent in Than you have begin to heat up the extragent in the cube. the cube. Vapours of the extragent are formed, raised in the Vapours of the extragent are formed, raised in the reflux-condenser, where they condensates and reflux-condenser, where they condensates and go to collector. go to collector. Saturated extract again enters in the cube.Saturated extract again enters in the cube.

The process extraction in apparatus of Soxhlet is The process extraction in apparatus of Soxhlet is continued until the BAS are completely extracted continued until the BAS are completely extracted and the extract in the flask is then processed.and the extract in the flask is then processed.

The advantage of this method:Large amounts of HRM can be extracted with a much

smaller quantity of solvent. This effects tremendous economy in terms of time,

energy and consequently financial inputs. At small scale, it is employed as a batch process

only, but it becomes much more economical and viable when converted into a continuous extraction procedure on medium or large scale.

Continuous extraction with an opposite Continuous extraction with an opposite movement of HRM and extragent to movement of HRM and extragent to meet each other in special extractorsmeet each other in special extractors

HRM and extragent are continuously loaded into the HRM and extragent are continuously loaded into the extractor from opposite hopper and moving extractor from opposite hopper and moving toward each other.toward each other.

The degree of exhaustion of HRM is governed by The degree of exhaustion of HRM is governed by the length of the apparatus and unload speeds of the length of the apparatus and unload speeds of HRM and extragent.HRM and extragent.

Equipment for Equipment for Continuous extraction Continuous extraction with an opposite movement of HRM with an opposite movement of HRM and extragent to meet each other in and extragent to meet each other in

special extractorsspecial extractors

1.1. Horizontal screw (Horizontal screw (helix)helix) extractor extractor

2.2. Vertical screw (Vertical screw (helix)helix) extractor extractor

3.3. Disk extractor Disk extractor

4.4. Extractor with spring-bladesExtractor with spring-blades

Horizontal screw extractorHorizontal screw extractor

1.1. HopperHopper

2.2. Inlet for Inlet for extragentextragent

3.3. Outlet for Outlet for extractextract

4.4. Helix Helix (screw)(screw)

5.5. Inclined Inclined helixhelix

Vertical screw (Vertical screw (helix)helix) extractor extractor

1.1. Loading columnLoading column

2.2. Helix to combine Helix to combine

3.3. Extractive columnExtractive column

4.4. Inlet for extragentInlet for extragent

5.5. Outlet for extractOutlet for extract

6.6. Helix (screw)Helix (screw)

Disk extractorDisk extractor1. Extractive tube 1. Extractive tube 2, 5 Stars for movement of 2, 5 Stars for movement of

roperope3. Steam jacket 3. Steam jacket 6. Rope to which perforated 6. Rope to which perforated

disks are attacheddisks are attached7. Perforated disks7. Perforated disks8. Inlet for extragent8. Inlet for extragent9. Hopper 9. Hopper 10, 12 Collector of extragent10, 12 Collector of extragent11. Outlet for extragent 11. Outlet for extragent

Extractor with spring-bladesExtractor with spring-blades

1.1. BodyBody

2.2. Inlet for extragentInlet for extragent

3.3. Outlet for extractOutlet for extract

4.4. Camera is divided Camera is divided on the sectionson the sections

5.5. Drum with spring-Drum with spring-bladesblades

6.6. Plates for hittingPlates for hitting

10,11 hopper for 10,11 hopper for HRMHRM

Advantage of the methodsAdvantage of the methods1.1. The most effective method to get a extract with a The most effective method to get a extract with a

higher yield and lower costhigher yield and lower cost

2.2. Used a relatively small amount of extragentUsed a relatively small amount of extragent

3.3. Ability to automate the processAbility to automate the process

4.4. Little amount of the equipmentLittle amount of the equipment

5.5. Exclude the work of downloading of raw materialExclude the work of downloading of raw material

Methods of extracts purification Methods of extracts purification

1. 1. BoilingBoiling, then standing in cool place and , then standing in cool place and filtering.filtering.

2. 2. Boiling with adding of kaolin, Boiling with adding of kaolin, then standing then standing and filtering.and filtering.

3. Alcohol-purification method: 3. Alcohol-purification method: extract is evaporated to volume lees in twice, extract is evaporated to volume lees in twice,

adding of Ethylic Alcohol 96 % in double adding of Ethylic Alcohol 96 % in double amount, standing in cool place for 7 days. amount, standing in cool place for 7 days.

Transparent solution is poured off, alcohol is Transparent solution is poured off, alcohol is evaporated to obtaining soft extract.evaporated to obtaining soft extract.

Evaporation of extragent to soft Evaporation of extragent to soft extracts production extracts production

- is process increasing extract viscosity by is process increasing extract viscosity by removing of the extragent by evaporation in the removing of the extragent by evaporation in the vacuum at the temperature about vacuum at the temperature about 50 - 60 °C50 - 60 °C..

The state of art are cautious vacuum evaporation The state of art are cautious vacuum evaporation apparatus and evaporation temperatures not apparatus and evaporation temperatures not exceeding 55 C.exceeding 55 C.

The temperature in correlation with the evaporation The temperature in correlation with the evaporation time is of special importance for quality of this time is of special importance for quality of this step of manufacture, if the extract contains easily step of manufacture, if the extract contains easily volatile or thermo- labile constituents.volatile or thermo- labile constituents.

Evaporators are used to concentrate a solution, separating Evaporators are used to concentrate a solution, separating the vapour from the solution. the vapour from the solution.

All evaporation equipment contains a heat exchanger for All evaporation equipment contains a heat exchanger for heating the process solution and a means to effectively heating the process solution and a means to effectively separate the vapour from the residual liquid, called a separate the vapour from the residual liquid, called a vapour separator. vapour separator.

Evaporator performance is rated by L per hour or Kg per hour Evaporator performance is rated by L per hour or Kg per hour of evaporation. of evaporation.

The greatest increase in steam economy is achieved by The greatest increase in steam economy is achieved by reusing the vaporized solvent. This is done in a Multiple reusing the vaporized solvent. This is done in a Multiple Effect Evaporator by using the vapour from one effect as Effect Evaporator by using the vapour from one effect as the heating medium for another effect in which boiling the heating medium for another effect in which boiling takes place at a lower temperature and pressure. takes place at a lower temperature and pressure.

Another method of increasing the utilization of energy is to Another method of increasing the utilization of energy is to use a Thermo Compression evaporator, in which the use a Thermo Compression evaporator, in which the vapour is compressed so that it will condense at a vapour is compressed so that it will condense at a temperature high enough to permit its use as the heating temperature high enough to permit its use as the heating medium in the same evaporator. This type is also called a medium in the same evaporator. This type is also called a MVR or mechanical vapour recompression.MVR or mechanical vapour recompression.

Equipment for Equipment for evaporationevaporation of the of the extragentextragent

1.1. The rotary directly flow The rotary directly flow apparatusapparatus

2.2. Circulating vacuum Circulating vacuum evaporator by firm Simaxevaporator by firm Simax

3.3. Foam evaporatorFoam evaporator

The rotary directly flow The rotary directly flow apparatusapparatus

1. Body (corp)1. Body (corp)

2. Inlet for liquid extract2. Inlet for liquid extract

3. Separation camera 3. Separation camera

4. To 4. To backingbacking of drops of drops

5. To vacuum5. To vacuum

6. To dividing of extract on 6. To dividing of extract on the flowsthe flows

7. 7. ScrapersScrapers (blades) (blades)

8. Steam jacket8. Steam jacket

9. 9. ShaftShaft (rotor) rotating (rotor) rotating

10. Outlet for soft extract 10. Outlet for soft extract

Foam evaporatorFoam evaporator1. 1. PumpPump

2. Working capacity2. Working capacity

3. Partition3. Partition

4. Separator4. Separator

5. Nipple for vapour 5. Nipple for vapour

6. Devise for distribution6. Devise for distribution

7. Inlet for liquid extract7. Inlet for liquid extract

8. Camera for evaporation8. Camera for evaporation

9. Ventilator9. Ventilator

10. Nipple for condensed 10. Nipple for condensed extractextract

11. Horizontal hot tubes 11. Horizontal hot tubes

Circulating vacuum Circulating vacuum evaporator by firm Simaxevaporator by firm Simax

1. Flask-collector 1. Flask-collector 2, 3 Tubes of the heater2, 3 Tubes of the heater4. Flask for circulating of 4. Flask for circulating of

drops and vapors of drops and vapors of extragentextragent

5. Trunk 5. Trunk 6. Condenser6. Condenser7. Inlet for liquid extract7. Inlet for liquid extract8. Flask for extragent8. Flask for extragent9. Outlet for extragent9. Outlet for extragent10. Circulating tube for 10. Circulating tube for

vapors of extragent vapors of extragent 12. Heater12. Heater

The plans of fulfilling of the dry The plans of fulfilling of the dry extracts production extracts production ::

Evaporation stage is includedEvaporation stage is included

1. Obtaining of liquid extract 1. Obtaining of liquid extract

2. Purification of liquid extract2. Purification of liquid extract

3. Manstruum evaporation 3. Manstruum evaporation

4. Drying of slightly evaporated 4. Drying of slightly evaporated extractextract

5. Standardization5. Standardization

6. Packing, packaging and 6. Packing, packaging and labeling of final productlabeling of final product

Without evaporation stageWithout evaporation stage

1. Obtaining of liquid extract 1. Obtaining of liquid extract

2. Purification of liquid 2. Purification of liquid extractextract

3. Drying of liquid extract3. Drying of liquid extract

4. Standardization4. Standardization

5. Packing, packaging and 5. Packing, packaging and labeling of final productlabeling of final product

Drying of the extractsDrying of the extracts in the dry extracts in the dry extracts production is the process of moisture production is the process of moisture

removal to obtain solid or powdered product removal to obtain solid or powdered product with a moisture content less than 5%.with a moisture content less than 5%.

Drying of purified extracts can be fulfilled Drying of purified extracts can be fulfilled by two planes: by two planes:

1) Drying of liquid extract without evaporation 1) Drying of liquid extract without evaporation

2) Drying 2) Drying slightly condensed extractslightly condensed extract

after the evaporation stage.after the evaporation stage.

Equipment for Equipment for dryingdrying of of condensed condensed extractsextracts

1. 1. Vacuum drying Vacuum drying apparatus apparatus

Slightly evaporated Slightly evaporated extract is placed on extract is placed on trays by thin layer trays by thin layer and dried. Porous and dried. Porous mass is obtained mass is obtained which is milled.which is milled.

2. 2. Vacuum roller dryersVacuum roller dryers

Slightly evaporated Slightly evaporated extract is placed on extract is placed on the hot rollers which the hot rollers which rotate toward to each rotate toward to each other. It is dried and other. It is dried and milling simultaneous.milling simultaneous.

Equipment for Equipment for dryingdrying of liquid of liquid extractsextracts

1.1. Lyophilise or dye-sublimation Lyophilise or dye-sublimation drying - drying - freeze dryers.freeze dryers.

2.2. Spray dryer.Spray dryer.

Freeze dryersFreeze dryers

Equipment used to dry slightly Equipment used to dry slightly condensed extractscondensed extracts

1.1. CylindricalCylindrical--vacuum dryingvacuum drying

2. 2. VacuumVacuum--drying cupboarddrying cupboard