YaCheng YC-100 Integrated Extraction and Concentration System
| Brand | YaCheng / PILOTECH |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Model | YC-100 |
| Heating Power | 380 V / 27 kW |
| Extraction Vessel Capacity | 100 L |
| Batch Feed Range | 5–20 kg |
| Vacuum Range | 0 to −0.08 MPa |
| Temperature Control Accuracy | ±2 °C |
| Condenser Surface Area | 3 m² |
| Cooling Water Consumption | 3 t/h @ < 0.3 MPa |
| Construction Material | SUS304 stainless steel (contact surfaces) |
| Operating Pressure Range | Full vacuum to positive pressure |
| Concentrate Density Range | 1.10–1.38 (for herbal extracts) |
| Optional Ultrasonic Frequency Range | 15–60 kHz (focused transducer type) |
Overview
The YaCheng YC-100 Integrated Extraction and Concentration System is an engineered pilot-scale platform designed 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 the principles of heat-assisted maceration under controlled thermal and pressure conditions, combined with dynamic reflux circulation and low-temperature evaporative concentration. The system integrates a jacketed 100 L extraction vessel with a built-in falling-film or forced-circulation evaporator module, enabling continuous or batch-mode operation across aqueous, alcoholic, and organic solvent-based protocols (e.g., ethanol, ethyl acetate). Its closed-loop architecture ensures containment of volatile compounds—including essential oils—via integrated condensation and oil–water phase separation, minimizing fugitive emissions and supporting compliance with occupational hygiene and environmental safety standards.
Key Features
- Compact footprint (3–4 m²), plug-and-play installation requiring only electrical supply (380 V, 27 kW) and cooling water (3 t/h at < 0.3 MPa)
- Triple-layer stainless steel (SUS304) extraction tank: inner polished surface, middle导热油 heating jacket (pressure-free design), outer polyurethane insulation
- Thermal uniformity ensured by indirect导热油 circulation—eliminating direct flame or steam hazards during flammable solvent processing
- Integrated reflux condenser (3 m² tube-type surface area) and demister-equipped oil–water separator for quantitative recovery of volatile aromatics
- Dynamic circulation evaporation mode maintains high heat-transfer coefficients even at elevated viscosities (up to density 1.38), mitigating performance decay typical in conventional concentrators
- Full-pressure-range operability: vacuum (−0.08 MPa), atmospheric, and slight positive pressure modes supported
- Automated temperature control via Omron PID controller (±2 °C accuracy) with real-time monitoring of vessel and evaporator zones
- Hygienic bottom discharge with lift-assisted herb basket—ensuring complete residue removal without dead zones
- Optional focused ultrasonic module (15–60 kHz) for cell-wall disruption and enhanced mass transfer; operates at ambient temperature to preserve thermolabile phytoconstituents
Sample Compatibility & Compliance
The YC-100 accommodates solid–liquid extraction of dried or fresh plant biomass (5–20 kg/batch), including roots, leaves, flowers, seeds, and fermented substrates. It supports USP , EP 2.8.23, and ISO 22000-aligned workflows for herbal product development. All wetted parts comply with FDA 21 CFR Part 11 requirements for material traceability and surface finish (Ra ≤ 0.8 µm). The system meets ASME BPE-2021 specifications for biopharmaceutical equipment design and conforms to CE machinery directive (2006/42/EC) and PED 2014/68/EU for pressure-containing components. Validation documentation—including IQ/OQ protocols, FAT/SAT reports, and material certificates—is provided upon request for GMP/GLP-regulated environments.
Software & Data Management
The integrated PLC-based control cabinet (Siemens S7-1200 series) delivers deterministic logic execution and audit-trail-capable data logging. Process parameters—including temperature setpoints, vacuum levels, condensate flow rate, and ultrasonic duty cycle—are timestamped and stored locally with optional Ethernet/IP or Modbus TCP export. The HMI interface supports multi-language configuration (English default) and allows recipe-driven operation with up to 99 programmable sequences. Data export formats include CSV and PDF for integration into LIMS or electronic lab notebooks (ELN). Electronic signatures, user-level access control (admin/operator/technician), and 21 CFR Part 11-compliant electronic records are enabled via optional software licensing.
Applications
- Preclinical and clinical-stage herbal extract development in academic pharmacognosy labs (e.g., Beijing University, Hong Kong University of Science and Technology)
- Process optimization studies for active ingredient yield, solvent selection, and energy efficiency benchmarking
- GMP-compliant pilot batches for nutraceutical, functional food, and cosmeceutical manufacturing (e.g., Zhejiang Baixing Food, Harbin Pharmaceutical Group)
- Essential oil recovery from citrus peel, mint, lavender, and eucalyptus feedstocks
- Solvent recycling loops for ethanol, methanol, and dichloromethane—reducing VOC emissions and disposal costs
- Tea polyphenol and fruit anthocyanin isolation under oxygen-limited, low-temperature conditions
- Validation of alternative extraction technologies (e.g., ultrasound-assisted vs. conventional reflux) per ICH Q5A and Q5C guidelines
FAQ
What solvents are compatible with the YC-100 system?
Water, ethanol, methanol, isopropanol, ethyl acetate, and other low-boiling-point organic solvents may be used—provided flash point and vapor pressure fall within the operational envelope of the vacuum pump and condenser.
Can the system handle heat-sensitive compounds?
Yes. The vacuum concentration module enables boiling point depression, allowing effective solvent removal below 40 °C. Optional ultrasonic extraction further reduces thermal load by enabling ambient-temperature mass transfer.
Is validation support available for regulatory submissions?
Yes. YaCheng provides IQ/OQ documentation templates, calibration certificates for all sensors (PT100, vacuum transducer, flow meters), and material traceability dossiers aligned with ISO 9001 and ISO 13485 quality management systems.
What maintenance intervals are recommended?
Daily visual inspection of gaskets and sight glasses; quarterly verification of vacuum integrity and temperature sensor calibration; annual replacement of water-ring pump seals and condenser tube cleaning per ASTM E2912-13 guidelines.
Does the system meet international electrical safety standards?
Yes. It carries CE marking for EMC Directive 2014/30/EU and Low Voltage Directive 2014/35/EU, with IP54-rated control cabinet and UL-listed heating elements.
