Executive Summary
An Ayurvedic and nutraceutical manufacturer required a fully automated, GMP-oriented Shatavari Extraction Plant for producing premium Shatavari Extract, Shatavarin-Rich Extract, Steroidal Saponin Extract, and standardised botanical ingredients for domestic and international pharmaceutical and nutraceutical markets.
The customer required a turnkey processing facility capable of maximising shatavarin recovery, preserving heat-sensitive phytochemicals, minimising solvent and utility consumption, and consistently manufacturing export-quality products to the customer's quality and regulatory requirements, with documentation to support qualification.
Mechotech successfully designed, engineered, manufactured, supplied, installed, and commissioned a Shatavari Extraction Plant integrating raw material preparation, hydro-alcoholic extraction, membrane clarification, solvent recovery, vacuum concentration, resin purification, spray drying, and intelligent PLC-SCADA automation.
Customer Background
The customer manufactures herbal ingredients for Ayurvedic medicine manufacturers, nutraceutical companies, pharmaceutical companies, women's health supplement brands, herbal product manufacturers, functional food companies, contract manufacturing organisations (CMOs), and international botanical ingredient exporters. The increasing global demand for women's wellness, reproductive health, adaptogenic herbs, and Ayurvedic formulations encouraged the customer to establish a modern GMP-oriented manufacturing facility.
Customer Challenges
Before modernisation, the customer experienced:
- Low shatavarin recovery
- Variable steroidal saponin content
- High solvent consumption
- Long extraction cycles
- Manual production inconsistencies
- High utility costs
- Batch-to-batch variability
- Limited production capacity
- Difficulty meeting export specifications
Project Objectives
Mechotech developed a turnkey solution capable of:
- Processing 15 MT/day of Shatavari Roots
- Producing standardised Shatavari Extract
- Manufacturing high-purity steroidal saponin extracts
- Recovering extraction solvent for reuse
- Preserving bioactive compounds
- Reducing operating costs
- Documentation to support the customer's quality and regulatory qualification
- Supporting future expansion
Raw Material
- Botanical Name
- Asparagus racemosus
- Common Name
- Shatavari
- Plant Part Used
- Roots
- Major Bioactive Compounds
- Shatavarins I–IV, Steroidal Saponins, Isoflavones, Alkaloids, Polyphenols
- Daily Processing Capacity
- 15,000 kg/day
Finished Product
Available Options
Applications
- Women's Health Supplements
- Fertility Support Products
- Ayurvedic Medicines
- Adaptogenic Formulations
- Functional Foods
- Herbal Capsules
- Tablets
- Nutraceutical Products
Process Flow
Process Description
Raw Material Preparation
Premium-quality Shatavari roots are cleaned, sorted, sliced, and milled into an optimised particle size to maximise extraction efficiency while preserving phytochemical integrity.
Hydro-Alcoholic Extraction
Prepared root material is extracted using pharmaceutical-grade hydro-alcoholic solvents under carefully controlled process conditions.
The extraction process ensures:
- High shatavarin recovery
- Uniform extraction efficiency
- Reduced degradation
- Consistent batch quality
Filtration
The crude extract is clarified through pressure filtration systems to remove insoluble plant particles before concentration.
Vacuum Solvent Recovery
The filtered extract enters high-efficiency vacuum evaporators where extraction solvent is recovered, purified, and recycled.
Benefits include:
- Reduced solvent costs
- Improved process safety
- Environmental sustainability
Vacuum Concentration
The clarified extract is concentrated under vacuum at controlled temperatures to preserve heat-sensitive bioactive compounds.
Membrane Clarification
Advanced membrane filtration systems remove fine suspended particles while preserving active phytochemicals.
Advantages include:
- Improved clarity
- Enhanced purity
- Better downstream processing
- Reduced product loss
Resin Purification
Adsorption resin technology selectively enriches steroidal saponins while removing undesirable impurities.
This stage provides:
- Higher active concentration
- Better colour
- Improved stability
- Pharmaceutical-grade quality
Standardisation
The purified extract is standardised according to customer requirements. Typical specifications include:
- Total Shatavarins
- Steroidal Saponins
- Polyphenols
- Moisture
- Bulk Density
- Particle Size
Spray Drying
The standardised extract is converted into a free-flowing powder suitable for capsules, tablets, sachets, and functional food formulations.
Quality Standardisation
Each production batch is analysed for:
- Total Shatavarins
- Steroidal Saponins
- Polyphenols
- Residual Solvent
- Moisture
- Heavy Metals
- Pesticide Residues
- Microbial Limits
- Particle Size
- Bulk Density
Major Equipment Supplied
- Root Washing System
- Root Cutting Machine
- Hammer Mill
- Stainless Steel Extraction Vessels
- Solvent Storage Tanks
- Pressure Leaf Filters
- Vacuum Evaporators
- Solvent Recovery System
- Membrane Filtration System
- Resin Purification Columns
- Spray Dryer
- Ribbon Blender
- Product Storage Silos
- PLC-SCADA Automation Panel
- Electrical MCC
- Instrumentation Package
- CIP/SIP System
Automation Features
The plant incorporates intelligent PLC-SCADA automation featuring:
- Automatic Recipe Management
- Extraction Sequence Control
- Temperature Monitoring
- Pressure Monitoring
- Solvent Flow Monitoring
- Vacuum Control
- Membrane Performance Monitoring
- Resin Column Automation
- Spray Dryer Automation
- Batch Traceability
- Alarm Management
- Utility Monitoring
- Production Analytics
- Industry 4.0 Connectivity
GMP & Safety Features
The plant is designed with hygienic, GMP-oriented practice in view; the standards that apply to the client's facility and product are scoped per project. Features include:
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- Closed-loop solvent extraction
- Explosion-proof electrical systems
- Nitrogen blanketing
- Food & pharmaceutical-grade elastomers
- CIP & SIP compatible systems
- Validation-ready equipment
- GMP-oriented layout
- HACCP-oriented engineering
Plant Utilities
- Steam Boiler
- Cooling Tower
- Chilled Water System
- Vacuum System
- Air Compressor
- RO Water System
- Soft Water System
- Electrical Power
- Nitrogen Supply
Sustainability Features
The plant incorporates environmentally responsible engineering through:
- Closed-loop solvent recovery
- Heat recovery systems
- Low-energy vacuum concentration
- Water conservation
- Utility optimisation
- Reduced emissions
- Sustainable extraction technology
- Eco-friendly manufacturing practices
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher shatavarin recovery
- Closed-loop solvent recovery
- Designed for efficient operation
- Reduced utility consumption
- Increased manufacturing capacity
- Improved export competitiveness
- Reliable pharmaceutical-grade quality
- Documentation to support regulatory qualification
Plants Used In This Project
Why Mechotech?
Mechotech is a manufacturer of turnkey extraction plants for nutraceuticals, pharmaceuticals, Ayurvedic medicines, botanical extracts, food ingredients, and specialty herbal products. With engineering expertise, our advanced extraction technologies, membrane purification systems, solvent recovery solutions, adsorption technologies, and PLC-SCADA automation enable customers worldwide to manufacture premium botanical ingredients.
Conclusion
The Shatavari Extraction Plant from Mechotech provides a complete turnkey solution for manufacturing premium standardised Shatavari Extract, steroidal saponin-rich extracts, and botanical ingredients for Ayurvedic and nutraceutical applications. Through advanced extraction, intelligent automation, and GMP-oriented engineering, the facility combines these process stages in a single turnkey solution.
Key Technical Highlights
- Raw Material
- Asparagus racemosus (Shatavari Root)
- Finished Products
- Shatavari Extract, Steroidal Saponin Extract, Water-Soluble Shatavari Extract
- Technology
- Hydro-Alcoholic Extraction + Membrane Clarification + Resin Purification + Spray Drying
- Solvent Recovery
- Established during process development
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS 304 / SS 316L
- Compliance
- Hygienic, GMP-oriented design with documentation to support the client's qualification; applicable standards are scoped per project
- Applications
- Ayurvedic Medicines, Nutraceuticals, Women's Health Supplements, Functional Foods, Herbal Pharmaceuticals
Why Global Manufacturers Choose Mechotech
- engineering excellence in botanical extraction and Ayurvedic process engineering
- Complete turnkey execution from laboratory validation to commercial production
- Customised plants from 100 kg/day pilot systems to industrial facilities
- Advanced extraction, purification, and standardisation technologies
- Intelligent PLC-SCADA automation with complete batch traceability
- High-efficiency solvent recovery systems
- Hygienic, GMP-oriented design with documentation to support the client's qualification; applicable standards are scoped per project
- Comprehensive installation, validation, operator training, preventive maintenance, spare parts support, and lifetime technical assistance
- Proven expertise in herbal extracts, nutraceuticals, pharmaceuticals, Ayurvedic products, natural colours, oleoresins, essential oils, and specialty botanical processing plants
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