Green Tea Extract
Green Tea Extract
Purity Levels
25% to 95% Polyphenols by UV & 50% EGCG 99% Caffeine, 40% catechins
Extraction Technologies
Mechotech designs and manufactures turnkey herbal extraction plants for Green Tea Extract, standardised to 25% to 95% Polyphenols by UV & 50% EGCG 99% Caffeine, 40% catechins. We supply the complete machinery — leaf preparation, low-temperature hydro-alcoholic extraction, membrane clarification, purification, solvent recovery, and drying — to convert tender Camellia sinensis leaves into a consistent, catechin-rich extract for the pharmaceutical, nutraceutical, food, and beverage industries.
Mechotech's Green Tea Extract plant is engineered around the real processing chemistry of Camellia sinensis: low-temperature hydro-alcoholic extraction minimises oxidation of heat-sensitive catechins, while membrane clarification and resin/solvent purification selectively enrich EGCG and total polyphenols and reduce caffeine and chlorophyll to customer specification. Built in SS 304 / SS 316L with integrated closed-loop solvent recovery, PLC-SCADA automation and full batch documentation, each plant is delivered as a commissioned turnkey system configured to meet the 25% to 95% Polyphenols by UV & 50% EGCG 99% Caffeine, 40% catechins specification.
Technical Specifications
| Product | Green Tea Extract Plant |
|---|---|
| Botanical Name | Camellia sinensis |
| Raw Material | Tender green tea leaves |
| Plant Part | Leaf |
| Extract Type | Standardised polyphenol / EGCG / catechin extract powder |
| Standardisation | 25% to 95% Polyphenols by UV; up to 50% EGCG; 99% Caffeine; 40% total catechins |
| Extraction Method | Low-temperature hydro-alcoholic extraction (oxidation-minimised) |
| Product-contact Material | SS 304 / SS 316L, electropolished, CIP-cleanable |
| Filtration System | Pressure leaf filtration + cross-flow membrane clarification |
| Concentration System | Vacuum / falling-film evaporator |
| Drying System | Spray dryer (vacuum drying optional) |
| Automation | Configurable — manual, semi-automatic or fully automatic PLC-SCADA (recipe-based) |
| Plant Capacity | Configured to requirement — pilot to commercial scale |
| Utility Requirements | Steam, chilled/cooling water, compressed air, nitrogen, soft water, power (project-specific) |
| Compliance | GMP hygienic design; full documentation for qualification |
| Final Product Form | Free-flowing standardised powder; water-soluble extract on request |
Plant Capacities
| Plant Scale | Raw Material Throughput | Typical Use |
|---|---|---|
| Pilot | Configured to your feedstock and trial plan | Product development, parameter validation |
| Semi-Commercial | Configured between pilot and commercial scale | Contract manufacturing, scale-up trials |
| Commercial | Configured to raw-material supply and confirmed buyer volume | Commercial production at confirmed buyer volume |
Capacity is configured to raw-material supply and confirmed buyer volume; we recommend a pilot plant to validate process parameters before scaling.
Manufacturing Process
Each extraction method follows a different process — pick a method to see its steps.
Leaf Preparation
Dried green tea leaves are cleaned and milled to a uniform particle size for even solvent contact.
Counter-Current Loading
Milled leaf is fed into a multi-stage counter-current extractor, where fresh hot water / hydro-alcoholic solvent meets the most-depleted leaf and spent solvent meets the fresh feed.
Continuous Extraction
Solvent flows counter to the solids across stages for high, uniform polyphenol and catechin recovery with the least solvent per kg of leaf.
Miscella Collection
The polyphenol-rich extract is drawn continuously from the feed end of the extractor.
Concentration & Solvent Recovery
The extract is concentrated under vacuum and the solvent is recovered and recycled through the closed loop.
Standardisation & Drying
Assayed and adjusted to the target polyphenols / EGCG / catechins, then spray-dried to a free-flowing powder.
Leaf Preparation
Milled green tea leaf is loaded into the pressurised extraction vessel.
Subcritical Water Extraction
Water heated under pressure above 100 deg C (kept liquid) acts as a green, tunable solvent that dissolves catechins efficiently with no organic solvent.
Rapid Mass Transfer
Elevated temperature and pressure speed extraction, while short residence time protects heat-sensitive EGCG.
Separation
The aqueous extract is clarified by filtration to remove spent leaf solids.
Vacuum Concentration
The clarified extract is concentrated under vacuum at low temperature.
Standardisation & Drying
Standardised to polyphenols / EGCG and spray-dried to a free-flowing powder.
Leaf Preparation
Milled green tea leaf is slurried with the hydro-alcoholic solvent.
Ultrasonic Cavitation
High-frequency ultrasound generates cavitation that ruptures the leaf cell walls, releasing catechins rapidly at a lower temperature.
Low-Temperature Extraction
Short extraction cycles at reduced temperature preserve heat-sensitive EGCG and cut cycle time.
Separation & Solvent Recovery
Solids are removed by filtration / centrifugation and the solvent is recovered under vacuum.
Concentration
The miscella is concentrated under vacuum.
Standardisation & Drying
Assayed to the target polyphenols / EGCG and dried to a free-flowing powder.
Leaf Preparation & Conditioning
Milled leaf is slurried and pH/temperature conditioned to suit enzyme activity.
Enzymatic Treatment
Cellulase / pectinase / tannase degrade the leaf matrix, freeing bound polyphenols and improving catechin yield.
Extraction
The released catechins are extracted gently at mild temperature to protect EGCG.
Separation & Solvent Recovery
Solids are separated and any solvent recovered under vacuum.
Concentration
The extract is concentrated under vacuum.
Standardisation & Drying
Adjusted to specification and dried to a free-flowing powder.
Leaf Preparation & Conditioning
Milled leaf is slurried and conditioned for enzyme activity.
Enzymatic Pre-Treatment
Cell-wall-degrading enzymes loosen the leaf matrix and free bound polyphenols.
Ultrasound-Assisted Extraction
Ultrasonic cavitation is applied together with the enzyme action for a synergistic boost in catechin / EGCG yield and speed.
Extraction & Separation
Combined UAE + EAE extraction runs at mild temperature, followed by solid-liquid separation and polish filtration.
Concentration & Solvent Recovery
Ethanol / solvent is stripped under vacuum and recycled through the closed loop.
Standardisation & Drying
The concentrate is adjusted to specification and dried to a free-flowing powder.
Leaf Preparation
Milled green tea leaf is mixed with solvent in the microwave extraction vessel.
Microwave Heating
Microwave energy rapidly heats the moisture inside the leaf cells, building internal pressure that ruptures the cell walls.
Rapid Extraction
A very short, energy-efficient extraction delivers high polyphenol release with minimal solvent and time.
Separation
The extract is clarified by filtration or centrifugation to remove spent solids.
Concentration & Solvent Recovery
Solvent is removed under vacuum and recycled through the closed-loop system.
Standardisation & Drying
Assayed to the target polyphenols / EGCG and dried to a free-flowing powder.
Major Plant Equipment
- Raw material cleaning system
- Leaf size-reduction / milling system
- Stainless-steel jacketed extraction vessels
- Solvent storage tanks
- Plate heat exchangers
- Pressure leaf filters
- Cross-flow membrane filtration system
- Vacuum / falling-film evaporator
- Purification (resin/adsorption) columns
- Closed-loop solvent recovery unit & condensers
- Spray dryer
- Ribbon blender
- Storage tanks
- CIP (clean-in-place) system
- PLC-SCADA automation panel, electrical MCC & instrumentation
Plant Output
Case Study
Green Tea Polyphenol Extraction Plant — 50-98% Polyphenol & High-EGCG Project
See how this plant was engineered and delivered for a real project.
From Plant to Product
Green Tea Extract
This botanical is also in the product range of Sureka Life Sciences, our sister concern in botanical ingredients.
Applications
- Functional and sports-nutrition beverage formulations
- Nutraceutical capsule, tablet, and supplement manufacturing
- Pharmaceutical standardised ingredient supply
- Cosmetic and personal care active ingredients
- Food and flavour applications
- Export to regulated-market ingredient buyers
Key Features
GMP Hygienic SS 316L Construction
Electropolished SS 316L product-contact surfaces use GMP hygienic design, with CIP operation between batches.
Closed-Loop Solvent Recovery
Integrated recovery returns the solvent for reuse within the process; recovery performance is established during process development.
Standardised to Specification
In-process and batch-release assay are used to check the finished Green Tea Extract extract against its declared specification (25% to 95% Polyphenols by UV & 50% EGCG 99% Caffeine, 40% catechins).
Integrated Drying
A matched spray/vacuum dryer produces a free-flowing, low-moisture powder ready for encapsulation and blending.
Scalable Batch Capacity
Plants are configured to requirement from pilot scale upward, with modular expansion.
Frequently Asked Questions
Does Mechotech supply the complete machinery for Green Tea Extract?
What specification can the Green Tea Extract plant achieve?
What extraction method is used, and how is caffeine reduced?
What production capacities are available for the Green Tea Extract plant?
Which industries use the Green Tea Extract plant?
How does a Green Tea Extract plant compare to other polyphenol-rich botanical plants?
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