Batch-Type Extraction
Batch-Type Extraction
Mechotech engineers and manufactures the Batch Extractor as turnkey process equipment for pharmaceutical, nutraceutical, food, and botanical extraction lines that process feedstock as discrete, self-contained batches. A fixed charge of feed material is loaded, extracted for a set time, and fully discharged before the next charge begins — giving simple, flexible operation and easy multi-product changeover, in contrast to the continuous feed-in/discharge-out operation of Mechotech's Continuous Extractor. Each unit is designed around the client's specific process parameters and target output, then fabricated, installed, and commissioned by Mechotech as a single accountable scope.
The Batch Extractor is built in SS 316L (or a process-appropriate grade) with electropolished product-contact surfaces and integrated instrumentation, so it can be charged, processed, and cleaned in place as one complete cycle under PLC-based control. Because feed-in and discharge-out do not happen simultaneously, the vessel is fully emptied and prepared before the next charge starts, which simplifies changeover between different products or batch sizes at the cost of the cyclical, stop-start output rate a continuous or counter-current system avoids. Capacity is configured to the customer's requirement, from pilot-scale systems for process validation to larger commercial installations with modular expansion, and every unit is delivered with full documentation to support GMP and regulatory qualification.
Process Flow
Technical Specifications
| Technology | Batch solid-liquid extraction |
|---|---|
| Working Principle | A fixed charge of feed material is loaded, extracted for a set residence time, and fully discharged before the next charge begins |
| Extraction Mode | Discrete batch cycle — charge, extract, discharge |
| Product-contact Material | SS 316L (or process-appropriate grade), electropolished |
| Automation | PLC-based control |
| Capacity | Configured to requirement — pilot-scale to larger commercial installations with modular expansion |
| Compliance | GMP hygienic design |
Plant Capacities
| Plant Scale | Capacity | Typical Use |
|---|---|---|
| Pilot | Pilot-scale systems sized to the feed and target output | Process validation, product development |
| Semi-Commercial | Configured between pilot and commercial scale | Scale-up trials, contract manufacturing |
| Commercial | Larger commercial installations with modular expansion | Production at confirmed buyer volume |
Capacity is configured to the customer's feedstock, throughput and target output; we recommend validating parameters on a pilot system before scaling.
Manufacturing Process
Batch Charging
A fixed charge of prepared feed material is loaded into the extraction vessel to begin the batch cycle.
Solvent Addition
Solvent is charged to the vessel, either as a full soak or in staged additions, to contact the loaded feed material.
Extraction Hold
The feed and solvent are held in contact for the process-defined residence time, allowing target compounds to transfer into the solvent phase.
Miscella Drawoff
The solvent-and-extract solution (miscella) is drawn off from the vessel once the batch has reached its target extraction level.
Batch Discharge
Spent, solvent-wet marc is fully discharged from the vessel before the next charge, completing the batch cycle.
CIP & Changeover
The vessel is cleaned in place between batches or product changeovers, supporting flexible, multi-product operation.
Major Plant Equipment
- Batch extraction vessel
- Solvent charging system
- Miscella drawoff and collection manifold
- Batch discharge system
- CIP skid and spray-ball connections
- Instrumentation and control automation
- PLC-based control panel
Plant Output
Applications
- Pharmaceutical and nutraceutical process manufacturing
- Botanical and herbal extraction industries
- Food and flavour processing
- Multi-product contract manufacturing with frequent changeover
- R&D and pilot-scale extraction trials ahead of scale-up
- Export to regulated-market equipment buyers
Key Features
Simple, Flexible Batch Operation
A fixed charge is loaded, extracted, and fully discharged each cycle, giving straightforward operation and easy changeover between different products or batch sizes.
GMP Hygienic Construction
Electropolished product-contact surfaces use GMP hygienic design, and the vessel is cleaned in place (CIP) between batches.
Turnkey Engineering
Design, fabrication, installation, and commissioning are delivered as one accountable scope, so the client deals with a single engineering team from drawing to handover.
Scalable Capacity
The extractor is sized to the customer's requirement, from pilot-scale validation through to commercial capacity, with modular expansion as production grows.
Frequently Asked Questions
What is a Batch Extractor and how does it differ from continuous extraction?
Does Mechotech supply the complete Batch Extractor?
What capacities are available for the Batch Extractor?
Which industries use the Batch Extractor?
Why choose a Batch Extractor over a continuous or counter-current system?
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