YaCheng PILOTECH YC020 Pilot-Scale Multifunctional Extraction and Concentration System
| Key | Brand: YaCheng / PILOTECH |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Origin Category | Domestic (China) |
| Model | YC020 |
| Pricing | Upon Request |
| Tank Volume | 20 L |
| Batch Feed Capacity | 0.3–5 kg |
| Minimum Feed | 0.3 kg |
| Vacuum Range | 0 to −0.08 MPa |
| Temperature Control Accuracy | ±2 °C |
| Heating Power | 9 kW @ 380 V |
| Condenser Area | 0.5 m² |
| Cooling Water Consumption | 1 t/h @ <0.3 MPa |
| Construction Material | SUS304 Stainless Steel |
| Footprint | 2–3 m² |
| Operating Pressure Range | −0.08 MPa to +0.3 MPa (gauge) |
| Concentrate Density Range | 1.10–1.38 g/mL |
| Solvent Compatibility | Water, Ethanol, and Other Organic Solvents |
Overview
The YaCheng PILOTECH YC020 Pilot-Scale Multifunctional Extraction and Concentration System is an integrated, closed-loop laboratory and pilot-scale processing unit engineered for thermal reflux extraction, solvent-based extraction (including ethanol and other GRAS-approved organics), vacuum concentration, and volatile oil recovery. It operates on the principles of dynamic circulation extraction—where heated solvent continuously percolates through solid botanical matrix—and simultaneous thin-film evaporation under controlled vacuum. Designed for process development and scale-up validation, the system supports full thermodynamic control over temperature, pressure, and flow dynamics, enabling reproducible batch-to-batch performance across natural product isolation workflows. Its modular architecture integrates extraction, condensation, phase separation, and concentration into a single skid-mounted platform compliant with hygienic design standards for pharmaceutical, nutraceutical, and functional food R&D environments.
Key Features
- 20 L jacketed extraction vessel constructed entirely from electropolished SUS304 stainless steel, rated for operation under vacuum (−0.08 MPa), atmospheric, and mild positive pressure (up to +0.3 MPa gauge)
- Integrated thermal oil heating system with external circulation loop—eliminating internal pressure risk in the jacket and enhancing safety during organic solvent processing
- Dual-function condensation train comprising a 0.5 m² tubular condenser and a gravity-driven oil–water separator for selective recovery of volatile aromatic compounds (e.g., terpenes, monoterpenoids)
- Externally mounted forced-circulation evaporator enabling high-efficiency vacuum concentration; achieves final extract densities between 1.10 and 1.38 g/mL without thermal degradation
- Precision temperature regulation via Omron PID controller (±2 °C accuracy) with real-time monitoring at multiple zones: jacket inlet/outlet, extraction chamber, and condensate return line
- Water-ring vacuum pump system with adjustable suction capacity, supporting stable operation across variable load conditions and solvent vapor loads
- Full sanitary configuration: tri-clamp connections, drainable piping, CIP-compatible geometry, and FDA-compliant gasket materials (EPDM/FKM)
- Compact footprint (2–3 m²); plug-and-play installation requiring only 380 V/9 kW electrical supply and chilled water feed (1 t/h @ <0.3 MPa)
Sample Compatibility & Compliance
The YC020 accommodates diverse solid–liquid extraction matrices including dried herbal powders, granulated tea leaves, fruit pomace, and algal biomass. It supports aqueous, hydroalcoholic (e.g., 30–95% ethanol), and low-boiling organic solvent systems (e.g., ethyl acetate, acetone) within defined flash point and vapor pressure limits. All wetted surfaces meet ASME BPE-2023 surface finish requirements (Ra ≤ 0.6 µm), and the system is designed to support GLP-compliant documentation practices. While not certified to ISO 13485 or FDA 21 CFR Part 11 out-of-the-box, its data logging architecture (via analog/digital I/O modules) permits integration with validated SCADA or LIMS platforms for audit-ready electronic records. The vessel and auxiliary components conform to PED 2014/68/EU Annex I essential safety requirements when operated within specified pressure–temperature envelopes.
Software & Data Management
The embedded electrical control cabinet includes programmable logic controller (PLC)-based sequencing logic for automated cycle execution—including pre-heating, reflux initiation, condensate collection, vacuum ramping, and concentrate discharge. Temperature, vacuum, and power consumption are logged at 1-second intervals to internal SD storage and exportable CSV files. Optional RS485 Modbus RTU interface enables connection to third-party supervisory systems for remote parameter adjustment, alarm forwarding (e.g., overtemperature, low coolant flow), and trend analysis. Audit trail functionality—recording operator ID, timestamp, setpoint changes, and manual overrides—is configurable per institutional SOPs to align with ALCOA+ data integrity principles.
Applications
- Process development of herbal active ingredient isolation (e.g., curcuminoids, flavonoids, saponins) under GMP-aligned lab conditions
- Optimization of ethanol-based extraction kinetics for standardized botanical extracts used in clinical trial material manufacturing
- Recovery and quantification of essential oils from citrus peel, lavender, or mint biomass in flavor & fragrance R&D
- Concentration of heat-sensitive fruit juices (e.g., camu camu, acerola) under sub-ambient boiling points to preserve vitamin C and polyphenol integrity
- Solvent recycling studies—particularly for ethanol and isopropanol—via integrated condensation and phase separation
- Teaching platform for unit operations courses covering mass transfer, heat transfer, and process intensification in chemical and pharmaceutical engineering curricula
FAQ
What is the maximum allowable operating pressure for the extraction vessel?
The vessel is rated for continuous operation from −0.08 MPa (vacuum) to +0.3 MPa (gauge) at temperatures up to 150 °C.
Can the system handle corrosive solvents such as dilute acids or alkalis?
SUS304 construction provides adequate resistance to mild acidic or alkaline aqueous solutions below pH 2 or above pH 12 only for short-duration cleaning cycles—not for extended extraction. For aggressive chemistries, optional SUS316L upgrade is available.
Is the oil–water separator compatible with high-viscosity extracts?
Yes—the separator incorporates adjustable weir height and residence time control to accommodate viscosities up to 500 cP at 40 °C.
Does the system include validation documentation (DQ/IQ/OQ)?
Standard delivery includes factory acceptance test (FAT) reports and material traceability certificates. Site-specific IQ/OQ protocols and templates can be provided upon request for customer-led qualification.
What maintenance intervals are recommended for the water-ring vacuum pump?
Daily visual inspection of seal water level and temperature; quarterly replacement of vacuum pump vanes and bearing grease; annual full rebuild recommended under continuous operation.
