Herbal Extraction Plants

Aloe Vera Extraction Plant

Purity Levels

Up to 200:1 (200X) concentrated powder; gel & juice to customer specification

Mechotech designs and manufactures turnkey Aloe Vera extraction and processing plants that convert fresh Aloe Vera leaves (Aloe barbadensis Miller) into stabilised gel, juice, concentrate and spray- or freeze-dried powder. We supply the complete line — leaf washing, filleting, gel extraction, Aloin decolorization, filtration, pasteurization, concentration and drying — for the nutraceutical, pharmaceutical, cosmetic, personal-care, food and beverage industries.

Mechotech's Aloe Vera plant is engineered around the real processing chemistry of aloe: mechanical filleting and cold gel extraction preserve natural bioactives such as acemannan, while food-grade adsorption removes Aloin (yellow latex) for a clear, stable, export-grade extract. Built in hygienic SS 304 / SS 316L with CIP, PLC-SCADA automation and full documentation, each plant is delivered as a commissioned, performance-verified turnkey system to GMP, WHO-GMP, HACCP and FSSAI hygienic-design standards, with capacity and automation configured to the customer's requirement.

Technical Specifications

Product	Aloe Vera Extraction & Processing Plant
Botanical Name	Aloe barbadensis Miller
Raw Material	Fresh mature Aloe Vera leaves
Plant Part	Leaf (inner gel fillet)
Extract Type	Gel, juice, concentrate and spray/freeze-dried powder
Standardization	Up to 200:1 (200X) concentrated powder; gel/juice to customer specification
Extraction Method	Mechanical filleting & cold gel extraction (oxidation-minimised)
Decolorization	Food-grade adsorption for Aloin (yellow-latex) removal
Product-contact Material	SS 304 / SS 316L, CIP-cleanable
Filtration System	Multi-stage filtration
Concentration System	Low-temperature vacuum evaporator (optional)
Drying System	Spray dryer / freeze dryer (optional)
Automation	Configurable — manual, semi-automatic or fully automatic PLC-SCADA (recipe-based)
Plant Capacity	Configured to requirement — pilot to 20,000+ kg fresh leaves/day
Utility Requirements	Steam, chilled/cooling water, compressed air, soft & purified water, power (project-specific)
Compliance	GMP, WHO-GMP, HACCP, FSSAI; USFDA-ready hygienic design
Final Product Form	Liquid (gel/juice), concentrate, or free-flowing powder

Manufacturing Process

Leaf Reception & Washing

Fresh Aloe Vera leaves (Aloe barbadensis Miller) are inspected for maturity and freshness, then washed in stainless-steel bubble/conveyor washers with sanitised water to remove soil, dust and surface latex residues.

Sorting, Trimming & Filleting

Damaged leaves are removed and thorny edges trimmed; automated or semi-automatic filleting separates the inner gel fillet from the outer rind, minimising yellow-latex (Aloin) contamination while maximising gel recovery.

Gel Extraction

The inner gel is extracted on hygienic stainless-steel equipment designed to minimise oxidation and preserve natural bioactive compounds such as acemannan.

Decolorization (Aloin Removal)

Food-grade adsorption columns remove Aloin and pigments to produce a clear, stabilised Aloe Vera extract suitable for food, cosmetic and pharmaceutical applications.

Filtration & Pasteurization

The gel/juice is clarified through multi-stage filtration and pasteurised via a plate heat exchanger for microbial safety while protecting heat-sensitive actives.

Concentration (Optional)

A low-temperature vacuum evaporator concentrates the aloe to the required solids without thermal degradation, ready for juice, concentrate or drying.

Drying (Optional)

Spray or freeze drying converts the concentrate into a free-flowing powder, standardised up to 200:1 (200X).

Blending & Aseptic Filling

Finished gel, juice, concentrate or powder is blended to specification and aseptically filled or packed under GMP/HACCP controls with full batch traceability.

Major Plant Equipment

Leaf washing conveyor & bubble washer
Sorting and trimming stations
Filleting machine (gel/rind separation)
Gel extraction system
Stainless-steel collection tanks
Decolorization columns (Aloin removal)
Multi-stage filtration system
Plate heat exchanger & pasteurizer
Low-temperature vacuum evaporator
Spray dryer / freeze dryer
Storage tanks & aseptic filling system
CIP (clean-in-place) system
PLC-SCADA automation, electrical MCC & instrumentation

Plant Output

Aloe Vera GelAloe Vera JuiceAloe Vera ConcentrateSpray-Dried Aloe Vera Powder (up to 200:1 / 200X)Freeze-Dried Aloe Vera Powder

Case Study

Aloe Vera Extraction Plant — Turnkey Gel, Juice & Powder Project

See how this plant was engineered and delivered for a real project.

Applications

Nutraceuticals and health supplements
Functional and beverage-grade drinks
Cosmetics and personal-care actives
Pharmaceutical formulations
Food processing and ingredients
Export-grade ingredient supply

Key Features

Automated Filleting & Gel Recovery
Automated or semi-automatic filleting separates the inner gel from the rind, maximising gel yield while minimising Aloin (yellow-latex) contamination.
Decolorization & Aloin Removal
Food-grade adsorption removes Aloin and pigments to deliver a clear, stabilised, export-grade aloe extract for regulated markets.
Hygienic SS 304 / SS 316L Construction
CIP-cleanable stainless-steel product-contact surfaces meet GMP, WHO-GMP, HACCP and FSSAI hygienic-design requirements.
PLC-SCADA Recipe Automation
Recipe-based control with pasteurization validation, batch traceability and production reporting; configurable from manual to fully automatic.
Gel, Juice, Concentrate & Powder in One Line
Matched concentration, spray and freeze drying let a single plant produce liquid gel/juice, concentrate and standardised powder (up to 200:1 / 200X).

Frequently Asked Questions

What is an Aloe Vera extraction plant?

An Aloe Vera extraction plant is a turnkey line that converts fresh Aloe Vera leaves into stabilised gel, juice, concentrate and powder. Mechotech engineers the complete plant — washing, filleting, gel extraction, Aloin decolorization, filtration, pasteurization, concentration and drying — as a single herbal extraction plant that we build, install and commission.

What products can an Aloe Vera plant produce?

The plant produces Aloe Vera gel, juice and concentrate, plus spray-dried or freeze-dried Aloe Vera extract powder standardised up to 200:1 (200X). The product mix and grades — food, cosmetic or pharmaceutical — are configured to your market.

What extraction method is used for Aloe Vera?

Aloe Vera is processed by mechanical filleting and cold gel extraction — not solvent extraction — to preserve natural bioactives such as acemannan, followed by food-grade adsorption to remove Aloin (yellow latex) for a clear, stable extract. For solvent-extracted botanical concentrates, Mechotech also builds solvent extraction plants.

What is the capacity, and can the plant be customized?

Capacity is configured to your raw-material supply and target output, from pilot lines up to 20,000+ kg of fresh leaves per day. Layout, automation level and output mix are all customised; we recommend a pilot plant to validate parameters before scaling.

What material of construction and compliance does the plant meet?

Product-contact parts are built in SS 304 / SS 316L with CIP cleaning, engineered to GMP, WHO-GMP, HACCP and FSSAI hygienic-design norms with USFDA-ready documentation.

Does Mechotech provide turnkey installation and automation?

Yes. Mechotech is an Aloe Vera extraction plant manufacturer and supplier, delivering process design, equipment manufacturing, PLC-SCADA automation, installation, commissioning and after-sales support as one performance-verified turnkey system.

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Aloe Vera Extraction Plant