Extraction Equipment

SonoZyme™ Enzyme–Ultrasound Hybrid Extraction Plant

The MOT SonoZyme™ Hybrid Extraction System combines two proven intensification technologies — enzyme-assisted extraction and ultrasound-assisted extraction — into a single modular platform. Targeted enzymes such as cellulase, pectinase, hemicellulase and protease selectively break down cell-wall and membrane structures, while controlled ultrasonic cavitation further disrupts the loosened matrix and drives solvent penetration. Together, the two mechanisms address feedstocks that resist either technology alone, particularly protein-, pectin- and polyphenol-rich botanical materials and difficult fibrous matrices. Mechotech engineers turnkey SonoZyme systems configured to each feedstock, enzyme system and target compound.

A SonoZyme system is built around a sequential process by default: a substrate slurry is first conditioned and treated with a selected enzyme blend, allowing controlled enzymatic hydrolysis to loosen the cell-wall structure, before the slurry is circulated through an inline ultrasonic reactor to complete disruption and intensify mass transfer under controlled temperature. This sequential configuration is Mechotech's recommended first commercial design, since it gives easier process control, a lower risk of ultrasonic enzyme deactivation, and is easier to validate across different enzyme combinations and contract-processing scenarios. A simultaneous configuration, where enzymatic action and ultrasonic treatment run concurrently, is available as a configurable option for validated processes — it can offer shorter processing time, better mass transfer and potentially lower enzyme consumption, but requires pulsed ultrasound and tight temperature control to avoid excessive ultrasonic intensity deactivating the enzyme or local heat generation damaging sensitive actives, and each enzyme–material combination requires its own validation before scale-up. Mechotech builds the enzyme reaction/conditioning vessel, inline ultrasonic recirculation system, membrane purification stage, vacuum concentration and drying equipment in SS 316L to hygienic, GMP-oriented standards, with PLC/SCADA recipe management across the full process train. Capacity is developed from a 500-litre pilot/demonstration system through to standardized 2,000, 5,000 and 10,000-litre commercial modules.

Process Flow

Technical Specifications

Technology	Hybrid Enzyme-Assisted (EAE) + Ultrasound-Assisted (UAE) Extraction
Working Principle	Targeted enzymatic hydrolysis of cell-wall structures combined with acoustic cavitation from inline ultrasonic treatment
Process Configuration	Sequential (enzyme treatment followed by ultrasound) as the recommended first commercial design, or simultaneous operation as a configurable option for validated processes
Solids Loading	Typical starting range 5-20% (configurable; pilot trials required per material)
Enzyme Dosage	Typical starting range 0.1-2.0% of dry material (configurable; pilot trials required per material)
Enzyme-Treatment Temperature	Typical starting range 35-60°C, configured to the selected enzyme system
pH	Typical starting range 4.0-8.5, configured to the selected enzyme system
Enzyme Reaction Time	Typical starting range 45-180 minutes (configurable; pilot trials required per material)
Ultrasound Frequency	Typically in the 18-25 kHz range (configurable)
Ultrasound Treatment	Typical starting range 10-60 minutes, or controlled inline residence time
Total Hybrid Processing Time	Approximately 1.5-4 hours as a starting range, versus commonly 6-15 hours for conventional extraction of comparable materials (configurable; pilot validation required)
Product-contact Material	SS 316L
Automation	PLC/SCADA with recipe management
Compliance	GMP / cGMP hygienic design
Final Output	Liquid extract; optional concentrate or dried powder via downstream recovery and drying

Plant Capacities

Plant Size	Scale / Usage	Configuration Note
500 L	Pilot / Demonstration	Jacketed enzyme reactor with variable-speed anchor and high-shear agitators, enzyme-dosing skid, 5-10 kW inline ultrasonic recirculation with adjustable amplitude and pulsed operation, plate heat exchanger, inline UV/NIR monitoring, decanter/centrifuge or membrane filter, CIP skid, and sampling points before and after ultrasound. Handles approximately 25-75 kg of dry feedstock per batch, depending on slurry concentration, viscosity and raw material.
2,000 L	Commercial module	Standardised commercial-scale module, sized and configured to validated pilot parameters.
5,000 L	Commercial module	Standardised commercial-scale module, sized and configured to validated pilot parameters.
10,000 L	Commercial module	Standardised commercial-scale module, sized and configured to validated pilot parameters.

The recommended development route is a 500-litre pilot/demonstration system first, used to validate enzyme selection, process sequence and operating parameters for the specific raw material, followed by standardised 2,000, 5,000 and 10,000-litre commercial modules. All figures are configured to the customer's feedstock and throughput requirement; larger and custom capacities are available on request.

Manufacturing Process

Raw material milling

Botanical feedstock is milled to the validated particle size, giving the enzyme system good access to the cell-wall surface.

Slurry preparation

The milled material is dispersed in water or a buffer solution to form a substrate slurry at the configured solids loading.

pH & temperature conditioning

The slurry is adjusted to the pH and temperature range that suits the selected enzyme system, before dosing begins.

Enzyme dosing

A selected enzyme or enzyme blend — cellulase, pectinase, hemicellulase, protease or a customised combination — is metered into the slurry.

Controlled enzymatic hydrolysis

The dosed slurry is held to allow controlled hydrolysis of the cell-wall and structural components, loosening the matrix ahead of ultrasonic treatment.

Inline ultrasonic treatment

The enzyme-treated slurry is circulated through an inline ultrasonic reactor, where acoustic cavitation further disrupts the loosened matrix and intensifies solvent penetration.

Extraction completion under controlled temperature

The treated slurry is held under controlled temperature to complete extraction and allow target compounds to fully diffuse into the surrounding medium.

Enzyme deactivation (where required)

Where the final product specification requires it, the enzyme is deactivated — typically by a controlled heat step or pH shift — to halt further hydrolysis before separation.

Solid–liquid separation

Spent solids are separated from the liquid extract using a decanter, centrifuge or filter press, selected to the feedstock and slurry characteristics.

Membrane purification

The clarified extract is further purified by membrane filtration, removing fines and refining the extract ahead of concentration.

Vacuum concentration

The purified extract is concentrated under vacuum, reducing volume while protecting temperature-sensitive compounds.

Spray or freeze drying

The concentrate is finished to a stable powder by spray drying or freeze drying, depending on the product's thermal sensitivity and target form.

Major Plant Equipment

Jacketed enzyme reaction / conditioning vessel
Variable-speed agitation system
Enzyme dosing skid
pH and temperature monitoring & control loop
Inline ultrasonic recirculation system with adjustable amplitude and pulsed operation
Plate heat exchanger for temperature control
Extraction holding tank
Solid–liquid separation stage (decanter, centrifuge or filter press)
Membrane purification stage
Vacuum concentration system
Spray dryer or freeze dryer (configured to product form)
CIP skid
PLC/SCADA recipe management system

Plant Output

Liquid extractConcentrate or dried powder (spray-dried or freeze-dried, via downstream recovery and drying)

Applications

DORB / rice-bran protein recovery using protease and cellulase enzyme systems
Pectin extraction with controlled pectinase/cellulase enzyme systems
Fruit pomace polyphenol recovery using pectinase and cellulase combinations
Turmeric and curcuminoid extraction using cellulase in combination with ultrasound
Ashwagandha active-compound extraction using cellulase/pectinase enzyme systems
Gingerol extraction using cellulase in combination with ultrasound
Natural colour extraction using pectinase/cellulase enzyme systems
Plant protein extraction using protease and carbohydrase enzyme systems
Mucilaginous herb processing, evaluated case-by-case for the specific matrix
Delicate native enzyme or protein recovery, where mild, closely controlled conditions are required

Key Features

Sequential hybrid design as standard
Enzyme treatment followed by inline ultrasound is Mechotech's recommended first commercial configuration, giving easier process control, lower risk of ultrasonic enzyme deactivation, and easier validation across enzyme combinations.
Two intensification mechanisms in one platform
Selective enzymatic cell-wall disruption is combined with controlled ultrasonic cavitation, addressing fibrous, protein-, pectin- and polyphenol-rich feedstocks that resist either method alone.
Configurable simultaneous mode for validated processes
Where a specific enzyme–material combination has been validated, enzymatic action and ultrasonic treatment can run concurrently using pulsed ultrasound and tight temperature control, subject to process-specific validation.
Reduced solvent and energy demand versus conventional extraction
Combining enzymatic and ultrasonic intensification can shorten extraction cycles and reduce solvent and energy consumption compared with conventional extraction, with actual gains established per validated raw material rather than guaranteed universally.
Hygienic, GMP-oriented build
Product-contact parts in SS 316L with smooth, CIP-friendly finishes support pharmaceutical, nutraceutical and food-grade production.
Full automation & recipe management
PLC/SCADA control with recipe management governs enzyme dosing, temperature, pH, ultrasonic amplitude and batch sequencing, with energy, flow and batch-data recording for repeatable, traceable operation.

Frequently Asked Questions

What is the MOT SonoZyme™ Hybrid Extraction System?

MOT SonoZyme™ is a modular enzyme–ultrasound extraction platform that combines two of Mechotech's proven intensification technologies, Enzyme-Assisted Extraction and Ultrasound-Assisted Extraction, into a single system. Selective enzymatic cell-wall disruption is combined with controlled ultrasonic cavitation to improve recovery, shorten processing time and reduce solvent and energy consumption for feedstocks that resist either technology alone.

How does the enzyme and ultrasound treatment combine in SonoZyme?

In Mechotech's recommended sequential configuration, the substrate slurry is first conditioned and treated with a selected enzyme blend, allowing controlled enzymatic hydrolysis to loosen the cell-wall structure, before the slurry is circulated through an inline ultrasonic reactor to complete disruption. A simultaneous configuration, where enzymatic action and ultrasonic treatment run concurrently, is available for validated processes using pulsed ultrasound and tight temperature control.

Why is the sequential configuration recommended over simultaneous operation?

Sequential operation — enzyme treatment followed by ultrasound — gives easier process control, a lower risk of ultrasonic energy deactivating the enzyme, and is easier to validate across different enzyme combinations and contract-processing scenarios, which is why it is Mechotech's recommended first commercial design. Simultaneous operation can offer shorter processing time and potentially lower enzyme consumption, but excessive ultrasonic intensity can deactivate enzymes and local heat generation can damage sensitive actives, so every enzyme–material combination requires its own validation before scale-up.

What materials and applications suit a hybrid enzyme–ultrasound process?

The hybrid approach is well suited to protein-, pectin- and polyphenol-rich botanical materials and difficult fibrous matrices, including rice-bran or DORB protein, pectin extraction, fruit pomace polyphenols, turmeric and curcuminoids, ashwagandha actives, gingerols, natural colours and plant proteins. Mucilaginous herbs and delicate native enzymes or proteins are evaluated case by case, since they may need more conservative, closely controlled conditions.

What benefits does hybrid processing offer compared with conventional extraction?

Properly optimised hybrid processing may offer shorter extraction cycles, higher recovery of intracellular compounds, lower extraction temperature, reduced solvent consumption, improved protein or bioactive recovery, lower enzyme requirement than enzyme-assisted extraction alone, lower energy consumption per batch, and improved utilisation of agricultural by-products. Mechotech does not promise a fixed percentage improvement across all materials — benefits are established and validated separately for each raw material.

What is the recommended development route from pilot to commercial scale?

Mechotech recommends starting with a 500-litre pilot/demonstration system to validate enzyme selection, process sequence and operating parameters for the specific raw material, before scaling to standardised 2,000, 5,000 or 10,000-litre commercial modules. A 500-litre batch typically handles approximately 25 to 75 kg of dry feedstock, depending on slurry concentration, viscosity and the raw material.

Does Mechotech provide turnkey design, manufacture, installation and commissioning?

Yes. Mechotech designs, engineers and fabricates the complete SonoZyme hybrid extraction system, including the enzyme reaction vessel, dosing skid, inline ultrasonic recirculation system, separation and membrane purification stages, concentration and drying equipment, and PLC/SCADA recipe management, and installs and commissions it as a single performance-verified turnkey plant. We support the project from pilot validation through to commercial-scale commissioning, operator training and process validation.

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SonoZyme™ Enzyme–Ultrasound Hybrid Extraction Plant