Ultrasound-Assisted Extraction
Ultrasound-Assisted Extraction
Mechotech designs and manufactures turnkey Ultrasound-Assisted Extraction (UAE) plants, also called ultrasonic extraction systems, in which ultrasonic energy is applied to a solvent-and-solids slurry to enhance cell disruption and mass transfer. The mechanism is acoustic cavitation: bubbles form and collapse in the liquid and disturb the plant matrix around them. Mechotech lists Ultrasound-Assisted Extraction among the candidate technologies on its herbal, spice-oleoresin and pomace-anthocyanin product pages, and its Hybrid Extraction and Counter-Current Extraction + Ultrasound pages combine it with enzymatic treatment and with counter-current flow. Each system is configured around the client’s feedstock, solvent and target compound, then fabricated, installed and commissioned by Mechotech as a single scope.
Mechotech’s Ultrasound-Assisted Extraction plant is configured around a jacketed sonication vessel and circulation loop, with ultrasonic transducer or probe assemblies, temperature control, solid–liquid separation and solvent recovery, as Mechotech’s illustration shows with three ultrasonic probes on the extraction vessel, a circulation pump and heat exchanger, generator cabinets and a PLC panel. Electropolished SS 316L product-contact surfaces, CIP connections and PLC-based control of ultrasonic amplitude, temperature and flow support repeatable batches. The solvent, the ultrasonic frequency and power, the temperature and the cycle time are established with the client during process development and pilot validation.
Process Flow
Technical Specifications
| Technology | Ultrasound-Assisted Extraction (UAE) / Ultrasonic Extraction |
|---|---|
| Working Principle | Acoustic cavitation from ultrasonic energy disrupts cells and enhances solvent contact and mass transfer in a solvent-and-solids slurry |
| Ultrasonic Source | Transducer or probe assemblies on the extraction vessel, with generators; frequency and power configured in design |
| Operating Temperature | Controlled through a jacket and heat exchanger; set point configured to the feed and target compound |
| Solvent | Water, ethanol, hydro-alcoholic or other process-grade solvent, selected for the feed and target compound |
| Operating Modes | Batch with slurry circulation; flow-through arrangements configured in design |
| Product-contact Material | SS 316L (or process-appropriate grade), electropolished |
| Separation | Filtration or centrifugation of the extract from spent solids (configured in design) |
| Solvent Recovery | Evaporation and condensation, with recovered solvent returned for reuse (configured in design) |
| Automation | PLC-based control of ultrasonic amplitude, temperature and flow, with batch logging (configurable to SCADA) |
| Cleaning | CIP-capable product-contact circuit |
| Utilities | Electric power for generators, chilled / cooling water for the jacket, compressed air (project-specific) |
| Capacity | Configured to requirement — pilot to commercial |
| Compliance | GMP hygienic design; full documentation for qualification |
| Final Output | Liquid extract; concentrate or dried powder through downstream evaporation and drying |
Plant Capacities
| Scale | Typical Use | Configuration |
|---|---|---|
| Pilot / R&D | Method development and parameter validation on the client’s feed | Small sonication vessel and probe set |
| Production | Plant-scale extraction campaigns | Vessel and ultrasonic power sized to the batch |
| Large production | Higher-volume campaigns | Larger vessels or multiple units |
Vessel volume, ultrasonic power and cooling duty are sized to the feed, the solvent and the batch size; no fixed volumes or power ratings are quoted on this page.
Manufacturing Process
Feed & Solvent Charging
Milled botanical material and the selected solvent are charged to the sonication vessel to form a slurry. The solid-to-solvent ratio is set during process development.
Slurry Circulation
The slurry is agitated or circulated through the circulation loop so that fresh material reaches the ultrasonic zone and contact stays uniform.
Ultrasonic Irradiation
Transducers or probes apply ultrasonic energy to the liquid, which drives acoustic cavitation and enhances cell disruption and mass transfer.
Temperature Control
A jacket and heat exchanger hold the slurry within the set temperature range, since the ultrasonic energy adds heat to the liquid.
Extraction Hold
The mixture is held for the specified time, with in-process checks or timing used to decide the end of the cycle; the duration is set during process development.
Separation & Clarification
The extract is separated from the spent solids by filtration or centrifugation and clarified to remove fines.
Concentration & Solvent Recovery
Solvent is recovered by evaporation and the extract is concentrated to the target level; recovered solvent is returned for reuse.
Finishing & Cleanup
The concentrate is collected, or dried downstream where a powder is required, and the system is cleaned in place for the next batch.
Major Plant Equipment
- Jacketed sonication / extraction vessel (SS 316L, electropolished)
- Ultrasonic transducer or probe assemblies with generators
- Circulation pump and slurry loop
- Jacket heat exchanger / chiller for temperature control
- Filtration or centrifuge for solid–liquid separation
- Evaporator and condenser for concentration and solvent recovery
- Solvent and extract storage tanks
- CIP connections
- PLC-based control panel
Plant Output
Applications
- Botanical and herbal extraction lines, where Mechotech lists UAE among the candidate technologies on its herbal product pages (for example Ashwagandha)
- Anthocyanin and polyphenol extraction from fruit pomace, where Mechotech lists UAE on its pomace-anthocyanin pages (for example Blackcurrant Pomace Anthocyanin Extract)
- Spice oleoresin extraction, where Mechotech lists UAE on pages such as Cumin and Coriander
- Combination with enzymatic treatment in Mechotech’s Hybrid Extraction platform, and with counter-current flow in CC-UAE
- R&D, pilot studies and process scale-up
Key Features
Cavitation-Assisted Mass Transfer
Acoustic cavitation disturbs the plant matrix and the liquid boundary layer around each particle; the benefit for a feed is established in trials.
Temperature-Controlled Slurry
A jacket and heat exchanger hold the slurry within a set range, and the set point is chosen for the target compound.
Flexible Solvent Use
The plant can run water, ethanol or hydro-alcoholic solvents, selected for the feed and the target compound.
Amplitude, Temperature and Flow Control
PLC control with batch logging supports repeatable, traceable operation.
SS 316L, CIP-Capable Construction
Electropolished SS 316L product-contact surfaces and CIP connections support hygienic operation.
Pilot to Commercial Capacity
The system is configured to requirement from pilot scale upward, with modular expansion.
Frequently Asked Questions
Does Mechotech supply the complete Ultrasound-Assisted Extraction plant?
What capacities are available for the Ultrasound-Assisted Extraction plant?
Which industries use the Ultrasound-Assisted Extraction plant?
What is Ultrasound-Assisted Extraction?
How does the plant work?
What can the plant process?
Which solvents can be used?
Can UAE be combined with other technologies?
What information is needed to specify a ultrasound-assisted extraction plant?
Which related extraction pages does Mechotech list?
Ready to discuss your project?
Get a free quote and technical consultation from our engineering team.