TS-NS Series Multifunctional Extraction and Concentration Unit

Overview

The TS-NS Series Multifunctional Extraction and Concentration Unit is an integrated, bench-to-pilot-scale process system engineered for solvent-based solid–liquid extraction and subsequent vacuum concentration under controlled thermal conditions. It operates on the principles of dynamic reflux extraction—where heated solvent circulates continuously through a solid matrix—and low-pressure evaporation, enabling efficient mass transfer and volatile solvent recovery. Designed specifically for R&D laboratories and small-batch production environments, the unit supports both conventional thermal extraction (e.g., decoction, maceration, percolation) and advanced physical enhancement via high-intensity ultrasonic cavitation. Its modular architecture accommodates scalable batch volumes from 5 L to 100 L, making it suitable for method development, formulation optimization, and GLP-compliant process validation in pharmaceutical, nutraceutical, food science, and natural product research.

Key Features

• Compact footprint with plug-and-play utility requirements—only standard electrical supply and cooling water inlet are needed.
• Centralized PLC-controlled HMI interface with real-time monitoring and logging of temperature, pressure, vacuum level, stirring speed, and ultrasonic duty cycle.
• Dual-mode operation: standard thermal extraction or optional ultrasonic-assisted extraction using focused transducers (15–60 kHz selectable), enhancing cell wall disruption and solute diffusion without thermal degradation.
• SUS304 stainless steel construction throughout wetted parts; all internal and external welds electropolished to Ra ≤ 0.8 µm (300-grit finish) for corrosion resistance and cleanability.
• Triple-layer thermal insulation and open-frame structural design facilitate rapid heat-up, uniform temperature distribution, and full visual access during operation.
• Integrated CIP (Clean-in-Place) system with spray ball and programmable rinse cycles ensures reproducible cleaning validation per FDA 21 CFR Part 11 and EU GMP Annex 15 guidelines.
• Full-vessel arc geometry eliminates dead zones during heating, extraction, and discharge—ensuring complete material evacuation and residue-free cleaning.

Sample Compatibility & Compliance

The TS-NS unit processes diverse solid matrices including dried herbs, botanical powders, animal tissues, algal biomass, and synthetic polymer resins. It accommodates aqueous, hydroalcoholic, and organic solvents (e.g., ethanol, methanol, ethyl acetate, hexane) within defined flash point and vapor pressure limits. All models comply with ISO 14001 environmental safety standards and meet structural integrity requirements outlined in ASME BPVC Section VIII Div. 1 for low-pressure vessels. The control system supports audit trail generation, user-level access control, and electronic signature capability—enabling compliance with FDA 21 CFR Part 11, EU Annex 11, and ICH-GCP data integrity expectations. Equipment qualification documentation (DQ/IQ/OQ/PQ templates) is available upon request for GMP-regulated environments.

Software & Data Management

The embedded control software provides intuitive recipe management, parameter trending, and alarm history with timestamped event logs. Data export is supported in CSV and PDF formats, compatible with LIMS integration via Modbus TCP or OPC UA protocols. Optional add-ons include remote diagnostics via secure TLS-encrypted web interface, automated report generation aligned with USP <1058> analytical instrument qualification frameworks, and raw data archiving compliant with ALCOA+ principles (Attributable, Legible, Contemporaneous, Original, Accurate, Complete, Consistent, Enduring, Available). All firmware updates undergo version-controlled release testing and traceability documentation.

Applications

• Phytochemical isolation: standardized extraction of alkaloids, flavonoids, terpenes, and polysaccharides from plant materials under validated thermal or non-thermal (ultrasonic) conditions.
• Preformulation studies: solubility profiling, excipient compatibility screening, and active pharmaceutical ingredient (API) recovery yield optimization.
• Nutraceutical development: anthocyanin, curcuminoid, and polyphenol enrichment from food-grade botanicals at pilot scale.
• Volatile oil recovery: steam distillation–compatible configurations for citrus peel, mint, and eucalyptus oil isolation with condensate phase separation.
• Solvent recycling: closed-loop recovery of ethanol or isopropanol from extract streams via integrated condensation and collection.
• Process intensification: comparative evaluation of ultrasonic frequency, amplitude, and duty cycle on extraction kinetics and selectivity—supporting DOE-driven optimization.

FAQ

What regulatory standards does the TS-NS unit support for GMP-compliant operations?

It meets mechanical and control architecture requirements for pharmaceutical R&D under EU GMP Annex 15, USP <1058>, and FDA 21 CFR Part 11 when configured with audit-trail-enabled firmware and qualified user access controls.
Can the ultrasonic module be retrofitted to existing units?

Yes—ultrasonic transducer assemblies and matching impedance circuits are offered as field-installable kits with factory calibration certificates.
Is vacuum distillation possible across the full capacity range?

All models support vacuum concentration down to −0.08 MPa; however, optimal solvent recovery efficiency is achieved at ≥30 L capacity due to condenser surface area scaling.
How is temperature uniformity verified during IQ/OQ?

Calibrated PT100 sensors are installed at multiple radial and axial positions inside the extraction vessel; thermal mapping reports are generated per ISO/IEC 17025-accredited procedures.
Does the system support continuous feed or only batch operation?

The TS-NS is designed exclusively for batch-mode processing. For semi-continuous applications, we recommend pairing with auxiliary peristaltic feed modules and inline density sensors (available as accessories).