Marigold Lutein Extract
Marigold Lutein Extract
Purity Levels
40% to 70% Lutein
Extraction Technologies
Mechotech designs and manufactures turnkey herbal extraction plants that process marigold petals to recover lutein esters and lutein ester fraction, with a 40% to 70% Lutein specification listed for this product. We supply the machinery for the route selected after screening — raw-material preparation, extraction, separation, concentration or recovery, and drying or collection. Candidate extraction technologies for lutein esters and lutein ester fraction: Counter-Current Extraction (CCE), Supercritical CO₂ Extraction (SCFE), Ultrasound-Assisted Extraction (UAE), Hybrid Extraction and Microwave-Assisted Extraction (MAE) (5 in total).
For marigold petals with lutein esters and lutein ester fraction as the target, there are 5 candidate technologies: Counter-Current Extraction (CCE), Supercritical CO₂ Extraction (SCFE), Ultrasound-Assisted Extraction (UAE), Hybrid Extraction and Microwave-Assisted Extraction (MAE). Ethanol/water- or water-based media apply to the solid–liquid routes and supercritical CO₂ to non-polar fractions such as oils, with an ethanol modifier evaluated only where polar fractions are also needed. These are screening candidates rather than guarantees: the final technology, operating parameters and plant configuration are established during process development and pilot validation. Product-contact parts are built in SS 316L with CIP-cleanable design, and automation is configured to the project.
Technical Specifications
| Product | Marigold Lutein Extract Plant |
|---|---|
| Feedstock | Marigold petals |
| Part / Feed Form | Petals |
| Target Extract | Lutein esters and lutein ester fraction |
| Standardisation | 40% to 70% Lutein |
| Extraction Method | Counter-current, CO2, UAE, Hybrid, MAE |
| Technology Count | 5 |
| Product-contact Material | SS 316L, electropolished, CIP-cleanable |
| Automation | PLC-SCADA, configured to requirement |
| Plant Capacity | Reference project: 25 MT/day of marigold flowers (see the Marigold Lutein Extraction Plant case study) |
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 | Reference project: 25 MT/day of marigold flowers | Commercial production at confirmed buyer volume |
The commercial figure is the reference project described in the Marigold Lutein Extraction Plant case study. 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.
Raw-Material Preparation
Marigold petals are cleaned and size-reduced so lutein esters can be reached by the extraction medium; particle size and moisture are set during process development.
Counter-Current Loading
Prepared marigold petals are fed into a multi-stage solid–liquid counter-current extractor where fresh ethanol/water or a suitable food-grade solvent meets the most-depleted material.
Counter-Current Extraction
Solvent flows against the solids across stages to draw out lutein esters; bed flow and fines management are verified during pilot work.
Extract (Miscella) Collection
The lutein esters-bearing miscella is collected from the fresh-feed end while spent solids are discharged from the solvent-entry end.
Concentration & Solvent Recovery
Solvent is removed from the clarified lutein esters-bearing extract under vacuum and returned through a solvent-recovery loop; recovery performance is confirmed at pilot scale.
Standardisation & Drying
The lutein esters extract is assayed against the declared target specification and dried or supplied as a concentrate, according to the requirement.
Raw-Material Conditioning
Marigold petals are cleaned and conditioned so lutein ester fraction is accessible to supercritical CO₂; moisture and particle size are set during process development.
Extraction Vessel Loading
Conditioned marigold petals are charged into the high-pressure extraction vessel.
Supercritical CO₂ Extraction
Supercritical CO₂ passes through the charge and dissolves lutein ester fraction; an ethanol modifier can be evaluated where polar fractions are also required, and operating pressure and temperature are set in process development.
Separator Collection
Pressure is reduced in separator stages so the extracted lutein ester fraction drops out of the CO₂ and is collected.
CO₂ Recycle
Gaseous CO₂ is re-liquefied and recirculated to the extractor, limiting make-up gas demand.
Finishing & Packing
The collected lutein ester fraction is polished by filtration as needed and packed to the required specification.
Raw-Material Preparation
Marigold petals are cleaned and size-reduced so lutein esters can be reached by the extraction medium; particle size and moisture are set during process development.
Slurrying
Prepared marigold petals are slurried with ethanol/water or water in the extraction vessel.
Ultrasonic Cavitation
Ultrasound creates cavitation that disrupts the plant matrix and speeds release of lutein esters; probe intensity, temperature and filtration behaviour are piloted.
Separation
Spent solids are separated by filtration or centrifugation and the extract is clarified before concentration.
Concentration & Solvent Recovery
Solvent is removed from the clarified lutein esters-bearing extract under vacuum and returned through a solvent-recovery loop; recovery performance is confirmed at pilot scale.
Standardisation & Drying
The lutein esters extract is assayed against the declared target specification and dried or supplied as a concentrate, according to the requirement.
Raw-Material Preparation
Marigold petals are cleaned and size-reduced so lutein esters can be reached by the extraction medium; particle size and moisture are set during process development.
Stage Sequence Selection
A deliberate combined extraction train is used: the sequence of stages is selected for lutein esters in pilot screening and each stage is designed separately.
First Assisted Stage
The first stage releases lutein esters from the prepared feed under controlled conditions set for that stage.
Second / Combined Stage
The second stage completes recovery of lutein esters from the partially extracted material; stage conditions are optimised separately.
Separation & Concentration
Spent solids are removed and the combined extract is clarified and concentrated; solvent is recovered where a solvent is used.
Standardisation & Drying
The lutein esters extract is assayed against the declared target specification and dried or supplied as a concentrate, according to the requirement.
Raw-Material Preparation
Marigold petals are cleaned and size-reduced so lutein esters can be reached by the extraction medium; particle size and moisture are set during process development.
Medium Mixing
Prepared marigold petals are mixed with ethanol/water or water in the microwave extraction vessel.
Microwave Heating & Extraction
Controlled microwave heating drives lutein esters out of the prepared feed in a short cycle; heating, moisture, solvent safety and temperature-sensitive targets are controlled, with limits set during process development and pilot validation.
Separation
Spent solids are separated by filtration or centrifugation and the extract is clarified before concentration.
Concentration & Solvent Recovery
Solvent is removed from the clarified lutein esters-bearing extract under vacuum and returned through a solvent-recovery loop; recovery performance is confirmed at pilot scale.
Standardisation & Drying
The lutein esters extract is assayed against the declared target specification and dried or supplied as a concentrate, according to the requirement.
Major Plant Equipment
- Raw-material cleaning and size-reduction system
- Multi-stage counter-current extractor
- Solvent storage tanks and transfer pumps
- Ultrasonic extraction vessel with transducer system
- Combined extraction train (stage equipment per the selected sequence)
- Microwave extraction vessel with temperature and safety controls
- Supercritical CO₂ extraction vessels
- CO₂ pump, heat exchangers and chiller
- Separator vessels
- CO₂ recovery / recycle system
- Optional ethanol-modifier dosing skid
- Filtration / centrifugation system
- Vacuum evaporator
- Solvent recovery system with condensers
- Dryer (where a dried form is specified)
- CIP (clean-in-place) system
- Storage and finished-product tanks
- PLC-SCADA control panel and instrumentation
Plant Output
From Plant to Product
Marigold Extract
This botanical is also in the product range of Sureka Life Sciences, our sister concern in botanical ingredients.
Applications
- Pharmaceutical standardised ingredient supply
- Nutraceutical capsule, tablet, and supplement manufacturing
- Food, flavour, and beverage applications
- Cosmetic and personal care active ingredients
- Ayurvedic and traditional medicine preparations
- Export to regulated-market ingredient buyers
Key Features
Technology-Matched Process Design
The plant is configured around the 5 candidate technologies for this feedstock: Counter-Current (CCE), Supercritical CO₂ (SCFE), Ultrasound (UAE), Hybrid and Microwave (MAE).
Target-Specific Configuration
Equipment and process steps are selected around the lutein esters and lutein ester fraction target and the marigold petals feed form, and are finalised after pilot work.
Parameters Fixed After Pilot Trials
Recovery, selectivity, solvent or water duty, quality and cleaning are measured in pilot trials before final plant parameters are fixed.
SS 316L Hygienic Construction
Product-contact surfaces are SS 316L and CIP-cleanable, in a hygienic design suited to food, nutraceutical and pharmaceutical supply chains.
Configurable Automation
PLC-SCADA automation with recipe control can be configured to the project scope.
Frequently Asked Questions
What is a marigold extraction plant for lutein esters and lutein ester fraction?
Which plant part or feed form does the marigold plant process?
Does Mechotech supply the complete machinery for Marigold Lutein Extract?
What specification can the Marigold Lutein Extract plant achieve?
Which industries use the Marigold Lutein Extract plant?
Why do the candidate technologies target lutein esters and lutein ester fraction when the specification on this page is 40% to 70% lutein?
Which extraction technologies are suitable for marigold petals?
How does the marigold extraction process work?
What equipment does the marigold extraction plant include?
Which related Mechotech extraction pages cover the same material or target?
What capacity is available and is a pilot trial recommended?
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