Yacheng YC-100 Multifunctional Extraction and Concentration System

Overview

The Yacheng YC-100 Multifunctional Extraction and Concentration System is an integrated pilot-scale platform 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 the principles of heat-reflux extraction, dynamic circulation evaporation, and closed-loop phase separation—enabling precise control over temperature, pressure, and residence time across diverse solvent systems (aqueous, hydroalcoholic, or organic). Designed for laboratory-to-pilot transition, the system supports both conventional maceration and advanced process intensification strategies, including optional focused ultrasonic energy delivery to enhance mass transfer kinetics without thermal degradation. Its fully sealed architecture ensures containment integrity under negative, atmospheric, and positive pressure conditions—meeting fundamental requirements for safe handling of volatile solvents and thermolabile phytochemicals.

Key Features

• Compact footprint (3–4 m²), plug-and-play installation with standard 380 V power and cooling water supply
• Triple-layer stainless steel extraction vessel (SUS304): inner polished surface (Ra ≤ 0.4 µm), middle thermal oil jacket (pressure-free design), outer polyurethane insulation
• Integrated tube-type condenser (3 m² heat transfer area) coupled with a gravity-driven oil-water separator for quantitative recovery of volatile aromatic oils
• Thermal oil heating system ensures uniform temperature distribution—critical for reproducible solvent extraction and elimination of localized overheating during ethanol or acetone-based processing
• Onboard evaporative concentrator with dynamic circulation loop maintains high heat transfer efficiency even at elevated viscosities (final extract density: 1.1–1.38 g/mL)
• Automated temperature control via Omron PID controller (±2 °C accuracy) and real-time vacuum monitoring (0 to –0.08 MPa range)
• Hygienic discharge mechanism: bottom-mounted slag outlet with zero-dead-volume geometry; optional lift-assisted herb basket for operator safety and residue-free unloading
• Full-process containment: all wetted parts conform to ASME BPE surface finish standards; system rated for operation across –0.08 MPa to +0.3 MPa gauge pressure
• Optional ultrasonic module (15–60 kHz, probe-type, focused acoustic energy) enables cell-wall disruption at ambient temperatures—validated for enhanced yield of heat-sensitive actives (e.g., flavonoids, terpenoids, polysaccharides)

Sample Compatibility & Compliance

The YC-100 accommodates solid herbal matrices (dried roots, leaves, flowers, seeds), liquid infusions (tea extracts, fruit pressings), and semi-solid suspensions. It supports water, ethanol, methanol, ethyl acetate, and other GRAS-listed solvents—fully compliant with ICH Q5C stability guidelines for solvent selection in botanical product development. All contact surfaces meet FDA 21 CFR Part 11 requirements for material traceability and surface passivation verification. The system’s pressure-rated construction, sanitary valve train, and documented cleaning protocols align with EU Annex 15 (Qualification & Validation) and USP Analytical Instrument Qualification frameworks. Third-party IQ/OQ documentation packages are available upon request for GMP-regulated environments.

Software & Data Management

Standard configuration includes a PLC-based HMI panel with password-protected parameter logging, event timestamping, and exportable CSV data files. Optional upgrade to SCADA-integrated control software provides full audit trail functionality per FDA 21 CFR Part 11—including electronic signatures, user-level access control, and immutable record retention. All temperature, vacuum, and time-stamped process events are stored locally with backup capability to network drives. Data export formats support direct import into LIMS platforms (e.g., LabWare, Thermo Fisher SampleManager) and statistical process analysis tools (JMP, Minitab).

Applications

• Pilot-scale optimization of TCM decoction processes (e.g., Huang Qin, Gan Cao, Dang Shen) under controlled reflux and vacuum concentration
• Recovery and purification of essential oils from citrus peels, lavender, or eucalyptus via selective condensation and phase separation
• Development of standardized botanical extracts for nutraceutical, cosmetic, and functional food applications
• Solvent recycling workflows (e.g., ethanol recovery >95% purity) in compliance with ISO 14001 environmental management standards
• Comparative studies of ultrasonic-assisted vs. conventional extraction kinetics for polyphenol-rich matrices (green tea, grape pomace, rosemary)
• Process validation for scale-up to production-scale extraction trains (100 L → 500 L → 2000 L)

FAQ

What solvent systems are compatible with the YC-100?

Water, ethanol (10–95%), methanol, isopropanol, ethyl acetate, and acetone—provided flash point and vapor pressure fall within the system’s pressure/temperature safety envelope.

Can the system operate under inert gas blanket?

Yes—optional nitrogen purge interface is available for oxygen-sensitive extractions (e.g., anthocyanins, unsaturated fatty acids).

Is the ultrasonic module validated for regulatory submissions?

The probe-type transducer is CE-marked and supplied with calibration certificates traceable to NIST standards; IQ/OQ protocols for ultrasonic intensity mapping are included in the optional validation package.

What maintenance intervals are recommended for the vacuum pump?

Water-ring vacuum pump requires quarterly oil/water replacement and annual mechanical seal inspection—logbook templates and SOPs are provided in the commissioning documentation.

Does the system support remote monitoring?

Standard Ethernet port enables Modbus TCP communication; optional Wi-Fi gateway allows secure cloud-based dashboard access with TLS 1.2 encryption.