Mulberry Leaf Extract
Mulberry Leaf Extract
Purity Levels
1-Deoxynojirimycin (DNJ) By HPLC 1%
Mechotech designs and manufactures turnkey herbal extraction plants for Mulberry Leaf (Morus alba), processing dried leaf into an extract standardised to 1-Deoxynojirimycin (DNJ) By HPLC 1%. DNJ is a well-documented iminosugar alkaloid found specifically in mulberry leaf that acts as an alpha-glucosidase inhibitor, making it the recognised marker compound for standardising leaf extracts intended for blood-sugar-support use — and because DNJ occurs at naturally low concentration in the leaf, an assay target in the low single-digit percentage range is typical for this raw material. We supply the complete machinery to convert authenticated, cleaned mulberry leaf into a consistent, DNJ-standardised extract for the nutraceutical, functional-food, and pharmaceutical industries.
Mechotech's Mulberry Leaf plant is engineered around the specific chemistry of a water-soluble, low-concentration alkaloid target: DNJ partitions preferentially into aqueous and dilute hydro-alcoholic solvent systems rather than higher-proof alcohol, so extraction conditions are tuned toward polar solvent ratios and moderate temperature to maximise alkaloid recovery from the leaf matrix while avoiding excessive co-extraction of chlorophyll and leaf waxes. Because the target assay is a small fraction of the dry extract, in-process HPLC monitoring and tightly controlled concentration ratios are used to hit the declared specification reliably. Built in SS 316L with closed-loop solvent recovery, automated process control, and full batch documentation, each plant is delivered as a commissioned turnkey system engineered to the declared 1-DNJ By HPLC 1% specification.
Technical Specifications
| Product | Mulberry Leaf Extract Plant |
|---|---|
| Botanical Name | Morus alba |
| Raw Material | Dried Mulberry leaves |
| Plant Part | Leaf |
| Extract Type | Standardised dry extract (powder) |
| Standardisation | 1-Deoxynojirimycin (DNJ) By HPLC 1% |
| Extraction Method | Aqueous / dilute hydro-alcoholic extraction (closed, jacketed SS 316L extractors) |
| Product-contact Material | SS 316L, electropolished, CIP-cleanable |
| Filtration System | Plate-and-frame filter press with cartridge polish filtration |
| Concentration System | Falling-film / vacuum evaporator with closed-loop solvent recovery |
| Drying System | Spray dryer or vacuum tray dryer |
| Automation | PLC-SCADA with recipe management, batch traceability and production reporting |
| Plant Capacity | Configured to requirement |
| Utility Requirements | Steam, chilled/cooling water, compressed air, soft water, power (project-specific) |
| Compliance | GMP, HACCP hygienic design; full documentation for qualification |
| Final Product Form | Free-flowing standardised extract powder |
Plant Capacities
| Plant Scale | Leaf Throughput | Typical Use |
|---|---|---|
| Pilot | Configured to your feedstock and trial plan | Product development, DNJ-yield 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 | Export-grade continuous production for blood-sugar-support nutraceutical buyers |
Capacity is configured to raw-material supply and confirmed buyer volume; we recommend a pilot plant to validate parameters before scaling.
Manufacturing Process
Raw Material Authentication & Cleaning
Dried mulberry leaves are authenticated, checked for moisture, and cleaned of stalks and foreign matter, since leaf quality and harvest timing directly affect natural DNJ content.
Size Reduction
Cleaned leaf is milled to a uniform particle size to increase surface area for solvent contact and accelerate diffusion of the water-soluble alkaloid fraction.
Aqueous / Dilute Hydro-Alcoholic Extraction
Milled leaf is charged into closed, jacketed SS 316L extraction vessels and extracted with water or a dilute hydro-alcoholic solvent system under controlled, moderate temperature across multiple cycles, favouring recovery of the polar DNJ alkaloid fraction.
Solid-Liquid Separation & Filtration
The extract slurry is clarified through a plate-and-frame filter press followed by cartridge polish filters to remove leaf fibre and particulate before concentration.
Vacuum Concentration
The filtered extract is concentrated in a falling-film / vacuum evaporator under reduced pressure to protect the heat-sensitive alkaloid content while achieving the concentration ratio needed to reach specification.
Solvent Recovery
A closed-loop recovery system condenses and recycles the alcohol solvent used per batch for reuse.
Standardisation
The concentrate is assayed by HPLC for 1-Deoxynojirimycin content and adjusted to the declared 1-DNJ By HPLC 1% specification before drying.
Drying & Quality Control
The standardised Mulberry Leaf extract is spray- or vacuum-tray dried to a free-flowing, low-moisture powder, then released after HPLC assay, residual-solvent, heavy-metal, microbial, and moisture testing with full certificate-of-analysis documentation.
Major Plant Equipment
- Raw material cleaning system
- Leaf cutting mill / hammer mill (size reduction)
- Stainless-steel aqueous/hydro-alcoholic extraction vessels (jacketed, SS 316L)
- Solvent storage tanks
- Solvent transfer pumps
- Plate heat exchangers
- Plate-and-frame filter press / pressure leaf filter
- Cartridge polish filters
- Falling-film / vacuum evaporator
- Closed-loop solvent recovery system
- Condensers & vacuum pumps
- HPLC system for in-process DNJ assay
- Spray dryer / vacuum tray dryer
- CIP (clean-in-place) system
- Storage tanks & finished-product tanks
- PLC-SCADA control panel, electrical MCC & instrumentation
Plant Output
From Plant to Product
Mulberry Leaf Extract
This botanical is also in the product range of Sureka Life Sciences, our sister concern in botanical ingredients.
Applications
- Blood-sugar-support and diabetes-category nutraceutical capsule/tablet manufacturing
- Functional-food and functional-beverage ingredient supply
- Mulberry leaf tea and herbal-infusion product manufacturing
- Weight-management and metabolic-health supplement blends
- Pharmaceutical standardised botanical ingredient supply
- Traditional and Ayurvedic-style metabolic-support preparations
- Export to regulated-market nutraceutical ingredient buyers
Key Features
GMP Hygienic SS 316L Construction
Electropolished SS 316L product-contact surfaces use GMP hygienic design, with CIP operation between batches.
Polar-Solvent Extraction Tuned for DNJ
Aqueous/dilute hydro-alcoholic extraction conditions are configured to favour recovery of the water-soluble DNJ alkaloid over less-polar leaf constituents.
Closed-Loop Solvent Recovery
Integrated recovery returns solvent used per batch for reuse.
Standardised to Specification
In-process and batch-release HPLC assay are used to check the finished extract against its declared 1-DNJ By HPLC 1% specification, even though DNJ occurs at low natural concentration in the leaf.
Integrated Drying
A matched spray/vacuum dryer produces a free-flowing, low-moisture powder ready for encapsulation, tableting, and tea-blend applications.
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 Mulberry Leaf Extract?
Why is DNJ used as the standardisation marker for Mulberry Leaf extract?
What specification can the Mulberry Leaf Extract plant achieve?
What extraction method is used, and how much solvent is recovered?
What production capacities are available for the Mulberry Leaf Extract plant?
What is the typical cost and delivery timeline for a Mulberry Leaf Extract plant?
Which industries use the Mulberry Leaf Extract plant, and does the plant support GMP qualification?
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