Yacheng YC-050 Multifunctional Extraction and Concentration Unit

Overview

The Yacheng YC-050 Multifunctional Extraction and Concentration Unit is an integrated pilot-scale system engineered for the simultaneous extraction, solvent recovery, and vacuum concentration of botanical matrices—including traditional Chinese medicinal herbs, tea leaves, fruit juices, and aromatic plant materials. It operates on a closed-loop thermodynamic principle combining reflux extraction, dynamic circulation evaporation, and fractional condensation. The unit employs jacketed indirect heating via thermal oil circulation (pressure-free outer jacket), enabling safe, uniform temperature control during water, ethanol, or organic solvent-based extractions. Its design conforms to pharmaceutical-grade hygienic engineering standards: all wetted parts are constructed from electropolished SUS304 stainless steel, rated for operation under vacuum (up to −0.08 MPa), atmospheric, and mild positive pressure conditions. With a 50 L extraction vessel capacity and scalable batch processing (0.3–10 kg raw material per cycle), the YC-050 serves as a GMP-aligned platform for process development, formulation optimization, and analytical sample preparation in R&D laboratories and pilot plants.

Key Features

• Compact footprint (2–3 m²), plug-and-play installation requiring only electrical supply (380 V, 18 kW) and cooling water (< 0.3 MPa, 2 t/h)
• Triple-layer stainless steel extraction tank: inner polished chamber, middle thermal oil heating jacket, outer polyurethane insulation
• Integrated reflux condenser (2 m² tube-type surface area) and oil–water separator for quantitative recovery of volatile aromatic oils
• Dynamic circulation evaporator with vacuum-assisted low-temperature concentration (concentrate density: 1.10–1.38 g/cm³)
• Precision temperature control via Omron PID controller (±2 °C accuracy) across full operating range
• Hygienic sanitary safety valve, sight glasses, vacuum gauge, and PLC-based electrical control cabinet
• Bottom discharge with zero-dead-space herb basket lifting mechanism for residue removal
• Optional ultrasonic-assisted extraction module: focused transducer (15–60 kHz selectable), non-thermal cell disruption enhancing mass transfer kinetics and active compound yield

Sample Compatibility & Compliance

The YC-050 accommodates diverse botanical feedstocks—dried roots, leaves, flowers, fruits, and fermented biomass—in both solid–liquid and liquid–liquid configurations. It supports aqueous, hydroalcoholic (e.g., 30–95% ethanol), and low-boiling organic solvents (e.g., ethyl acetate, hexane) compatible with ICH Q5A residual solvent limits. All fluid-contact surfaces meet ASME BPE-2021 surface finish specifications (Ra ≤ 0.8 µm). The system complies with ISO 9001 manufacturing protocols and is routinely validated for GLP/GMP environments. Vacuum integrity testing, thermal mapping, and cleaning validation protocols align with FDA 21 CFR Part 11 data integrity requirements when paired with compliant software packages.

Software & Data Management

The standard control interface includes a programmable logic controller (PLC) with HMI touchscreen for setting and logging extraction time, temperature setpoints, vacuum level, and condensate collection volume. Optional Ethernet-enabled data acquisition modules support CSV export, real-time trending, and integration into LIMS or MES platforms. Audit trails record operator ID, parameter changes, alarm events, and cycle completion timestamps—fully traceable for regulatory submissions. Firmware updates follow IEC 62443 cybersecurity guidelines; no cloud connectivity is embedded by default to preserve network isolation in controlled laboratory environments.

Applications

• Process development of herbal monographs (e.g., *Ginkgo biloba*, *Panax ginseng*, *Scutellaria baicalensis*) under USP dissolution and extract standardization protocols
• Recovery of essential oils (e.g., lavender, peppermint, citrus) via steam distillation–condensation–separation workflows
• Preparative-scale isolation of polyphenols, flavonoids, and saponins from tea, berries, or marine algae
• Solvent recycling loops for ethanol or acetone in food-grade flavor concentrate production
• Stability-indicating method development for heat-labile actives (e.g., anthocyanins, terpenoids) using ultrasonic-assisted low-temperature extraction
• Academic research in phytochemistry, natural product pharmacology, and green process engineering

FAQ

What is the maximum allowable working pressure and vacuum range of the extraction vessel?

The vessel is rated for operation from −0.08 MPa (vacuum) to +0.3 MPa (gauge pressure), verified per ASME Section VIII Div. 1 hydrostatic test protocols.

Can the unit be validated for GMP manufacturing use?

Yes—design qualification (DQ), installation qualification (IQ), operational qualification (OQ), and performance qualification (PQ) documentation packages are available upon request, including FAT/SAT reports and calibration certificates.

Is solvent compatibility limited to ethanol and water?

No—the system is compatible with Class I–III solvents per NFPA 30, provided flash point and vapor pressure remain within the thermal oil jacket’s safe operating envelope (max 250 °C surface temp) and vacuum pump specifications.

How is cleaning verification performed between batches?

CIP (clean-in-place) is supported via dedicated rinse ports; residue limits are assessed using TOC analysis or HPLC-UV against pre-established acceptance criteria per PDA Technical Report No. 29.

Does the ultrasonic module affect long-term equipment reliability?

The transducer assembly is decoupled from the main vessel via titanium alloy waveguide; mean time between failures (MTBF) exceeds 8,000 hours under continuous duty at 20–40 kHz, per manufacturer’s accelerated life testing data.